Wayne-Dalton 8000, 8100, 8200 garage door Installation Instructions And Owner’s Manual

Ta b l e
8000 / 8100 / 8200
To r s i o n
Standard Lift and
Light Commercial
MH
Installation Instructions And Owner’s Manual
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.
O f
C o n t e n t s
Pre-Installation
Important Safety Instructions
Tools Required
Package Contents
Door Section Identification
Removing an Existing Door
Preparing the Opening
Parts Breakdown
Installation
Optional Installation
Inside Lock
Pull Down Rope
Maintenance
Cleaning Your Garage Door
Painting Your Garage Door
Operation And Maintenance
Warranty
2
2
2
2
3
4
4
5
6
18
18
18
19
19
19
19
21
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.
2. Door Heights greater than 8’0” (> 8’0”) are considered Light
Commercial 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
©Copyright 2013 Wayne-Dalton, a Division Of Overhead Door Corporation
Part Number
351651
NEW 02/12/2013
Pre-Installation
Important: Right and left hand is always determined from inside the building
looking out
Important Safety Instructions
Tools Required
Definition of key words used in this manual:
Warning
WARNING
• 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”
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 QUESTION ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A
TRAINED DOOR SYSTEMS TECHNICIAN DO THE INSTALLATION OR REPAIRS.
• Phillips head
screwdriver
• Locking Pliers
• (2) Vice clamps
• Wrenches: 3/8”,
7/16”, 1/2”, 9/16”,
5/8”
• 1/4” Torx bit
• Approved winding
rods
• Hammer
• Tape measure
• Step Ladder
• Level
• Pencil
• Leather gloves
• Safety glasses
Package Contents
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 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.
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, 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.
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)
Torsion shaft / Torsion keyed shaft (as required)
Torsion keyed shafts (as required)
Q.I. flag angles RH/LH (as required)
F.A. flag angles RH/LH (as required)
Vertical tracks RH/LH (as required)
Angle mount vertical track assemblies RH/LH (as required)
Riveted vertical track assemblies RH/LH (as required)
Horizontal tracks RH/LH (as required)
(2) Horizontal angles (as required)
Q.I. jamb brackets
(as required)
Track rollers
(as required)
F.A. jamb brackets
(as required)
Strut (U-shaped)
(if included)
Weather seals & nails
(If included)
Bottom corner
brackets (as required)
Pull rope
(if included)
(2) Bottom corner
brackets (as required)
Warning
WARNING
Prior to winding or making adjustments to the springs, ensure you’re winding in the proper direction as stated in the
Installation Instructions. Otherwise, the spring fittings may
release from spring if not wound in the proper direction and
could result in severe or fatal injury.
Graduated hinges
2
Top fixture
bases (as required)
Top fixture Top fixture assemblies
(as required)
slides (as required)
Counterbalance lift cables Torsion springs RH/LH End bearing bracket RH/LH (as required)
Center bracket (as required)
Cable drums RH/LH
(2) Lift handles
& spacers
Center bracket
bushing (as required)
Cotter ring
(1) Step plate
(Inside)
(1) Step plate
(Outside)
(2) Step plates
(as required)
Washers
(2) #8 x 1-5/8”
Self tapping screws (step plate)
Clevis pin
Door Section Identification
Center coupler
Keys
(as required) assembly (as required)
5/16” x 1-1/4”
Clevis pin
Stud Plate
(as required)
1/4”-20 x 11/16” Self
drilling screws (as required)
(2) Spacers
(as required)
Door Height Bottom
Cotter pin
1/4”-20 x 9/16”
5/16”-18 Hex
1/4” - 20 Hex
5/16”-18 x 3/4”
Track bolts (as required) Carriage bolts (as required) nuts (as required) nuts (lift handles)
(2) 3/8”- 16 Hex nuts
(as required)
1/4”-14 x 5/8” Self tapping
screws (as required)
1/4”-14 x 5/8”
Tamper resistant Self
drilling screws (as required)
1/4”- 20 Flanged
hex nuts (as required)
5/16” x 1-5/8” Tamper-resistant
hex head lag screws (as required)
3/8” - 16 x 1-1/2” Hex head bolts
(as required)
(2) 3/8”-16 x 3/4”
Truss head bolts
5/16” x 1 5/8” Hex head lag screws
(as required)
5/16” x 2” Tamper-resistant hex head
lag screw (as required)
Lock
(second)
Interme- Interme- Interme- Interme- Intermediate I diate II diate III diate IV diate V
(third) (fourth) (fifth)
(sixth) (seventh)
Top
6’0”
18”
18”
18”
6’3”
21”
18”
18”
18”
6’6”
21”
18”
18”
6’9”
21”
21”
21”
7’0”
21”
21”
21”
7’6”
18”
18”
18”
18”
18”
7’9”
21”
18”
18”
18”
21”
8’0”
21”
18”
18”
18”
8’3”
21”
21”
18”
18”
8’6”
21”
21”
21”
21”
18”
8’9”
21”
21”
21”
21”
21”
9’0”
18”
18”
18”
18”
18”
18”
9’3”
21”
18”
18”
18”
18”
18”
9’6”
21”
18”
18”
18”
18”
9’9”
21”
21”
18”
18”
18”
10’0”
21”
21”
21”
18”
18”
21”
10’3”
21”
21”
21”
21”
21”
18”
10’6”
21”
21”
21”
21”
21”
10’9”
21”
18”
18”
18”
18”
18”
18”
11’0”
21”
18”
18”
18”
18”
18”
21”
11’3”
21”
21”
18”
18”
18”
18”
11’6”
21”
21”
21”
18”
18”
18”
11’9”
21”
21”
21”
21”
18”
18”
21”
12’0”
21”
21”
21”
21”
21”
21”
18”
12’3”
21”
21”
21”
21”
21”
21”
12’6”
21”
18”
18”
18”
18”
18”
18”
21”
12’9”
21”
21”
18”
18”
18”
18”
18”
21”
13’0”
21”
21”
21”
18”
18”
18”
18”
21”
13’3”
21”
21”
21”
21”
18”
18”
18”
21”
13’6”
21”
21”
21”
21”
21”
18”
18”
21”
13’9”
21”
21”
21”
21”
21”
21”
21”
18”
14’0”
21”
21”
21”
21”
21”
21”
21”
21”
18”
21”
N/A
18”
21”
21”
N/A
21”
21”
N/A
21”
21”
21”
N/A
21”
21”
When installing your door you must use sections of the appropriate height in the right stacking order. What sections heights you need to use in what order depends on the height of your
door.
NOTE: Unless your door is five sections in height, you will not receive an Intermediate II
section.
1/4” - 20 x 2-1/2” Carriage bolts (as required)
1/4” - 20 x 2-3/4” Carriage bolts (as required)
3
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.
*NOTE: For door heights from 10’1” to 14’0”, refer to your operator manufacture installation
instructions for appropriate depth into room.
Backroom Requirements
Warning label
Intermediate I section
18”
or
21”
Door Height
Bottom corner bracket warning labels
Bottom weather seal
Bottom section
Section side
view illustration
Manual Lift
Motor Operated
6’0” to 7’0”
Track
102” (2591 mm)
125” (3175 mm)
7’1” to 8’0”
114” (2896 mm)
137” (3480 mm)
8’1” to 9’0”
126” (3200 mm)
168” (4267 mm)
138” (3505 mm)
168” (4267 mm)
10’1” to 12’0”
162” (4115 mm)
See *NOTE
12’1” to 14’0”
186” (4724 mm)
See *NOTE
12”, 15” Radius
9’1” to 10’0”
Removing an Existing Door
Headroom Requirements
Important: Counterbalance spring tension must always be released before
any attempt is made to start removing an existing door.
Track Type
Warning
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.
Space Needed
12” Radius
11” (279 mm)
15” Radius
14-1/2” (368 mm)
6” LHR Kit
6” (152 mm)
Suitable mounting surface
2”x 6” lumber minimum
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.
Headroom
Min. Side
room
Clearance
is 3 1/2”
Header board 2”x 6”
lumber preferred
Preparing the Opening
Min. Side
room
Clearance
is 3 1/2”
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 Torsion 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 Torsion 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 other track systems: 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
e
el h
Lev
rips
st
her
at
We
Plumb
jambs
Bac
kro
Nail
bs
om
Finished
Door
Height
ed
ish
Fin width
r
Doo
Jam
4
r
ade
Jamb
Quick Install track
Weatherstrips
Weatherstrips
Jamb
Other track systems 1/8” to 1/4”
Parts Breakdown
I3.
NOTE: The illustrations shown on this page are
general representations of the door parts. Each
specific door models may have unique variations.
I6.
I8.
I3.
I6. I5.
I8.
I8.
I4.
I9.
I6.
I7.
A1.
I6.
I5.
I4.
J1.
H1.
I1.
I5.
I3.
I3.
I2.
I7.
I5.
A2.
I8.
C1.
F1.
F3.
I1.
B1.
F2.
I7.
G1.
E1.
A2.
F1.
A1.
F2.
Top of vertical
track
Top of vertical
track
E2.
F3.
C1.
B2.
B2. (Fully
Adjustable
Feature)
3rd hole
set
E3.
H2.
K2.
E4.
H4.
H3.
K1.
D2.
2nd
hole set
B1. (Quick
Install
Feature)
2nd
hole set
H1.
D1.
C2.
B2.
J1.
Top
hole
C1.
1st hole
set
B1.
H4.
H3.
3rd
hole set
Middle
hole
Bottom
hole
1st
hole set
Lower hole
of hole/
slot pattern
H2. K1.
A. Flag Angles (As Required):
A1. Quick Install (Q.I.) Flag Angles
A2. Fully Adjustable (F.A.) Flag Angles
B. Jamb Brackets (As Required):
B1. Quick Install (Q.I.) Jamb Brackets
B2. Fully Adjustable (F.A.) Jamb Brackets
C. Track Rollers (As Required):
C1. Short Stem Track Rollers
C2. Long Stem Track Rollers
D. Graduated End Hinges:
D1. Single Graduated End Hinges (S.E.H.), Industry Standard
D2. 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 Fixture (As Required):
F1. Top Fixture Bases - (L-Shaped)
F2. Top Fixture Slides - (L-Shaped)
F3. Top Fixture Assemblies
G. Strut(s) (As Required):
G1. Strut (U-shaped)
H. Tracks (As Required):
H1. Left Hand and Right Hand Horizontal Track Assemblies
H2. Left Hand and Right Hand Vertical Tracks
H3. Left Hand and Right Hand Riveted Vertical Track Assemblies
H4. Left Hand and Right Hand Angle Mount Vertical Track Assemblies
I. Torsion Spring Assembly (As Required):
I1. Left Hand and Right Hand Torsion Springs (As Required)
I2. Counterbalance Lift Cables
I3. Left Hand and Right Hand End Bearing Brackets (As Required)
I4. Left Hand and Right Hand Cable Drums
I5. Center Bushing / Center Bearing (As Required)
I6. Center Bracket(s) (As Required)
I7. Torsion Shaft / Torsion Keyed Shaft / Torsion Keyed Shafts (As Required)
I8. Keys (As Required)
I9. Center Coupler Assembly (As Required)
J. Rear Back Hangs:
J1. Left Hand and Right Hand Rear Back Hang Assemblies
K. Bottom Corner Brackets (As Required):
K1. Left Hand and Right Hand Bottom Corner Bracket
5
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.
1
Horizontal track
angle
Quick
Install
tabs
Key slots
Quick Install tabs
in place
Alignment Horizontal
track
hole
Quick Install Flag Angles
Tools Required: None
Horizontal track
angle
Horizontal track
angle
Quick
Install tabs
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.
Quick
Install tabs
Key slots
Horizontal
track
Horizontal
track
1/4 Turn
Flag angle
Vertical
track
2
Fully Adjustable Flag Angles
3rd hole set
Jamb bracket
in place
Q.I. tab
Mounting flange
Q.I. jamb
bracket
Flag angle
1/4”-20
Flange hex nuts
Fully Adjustable
vertical
track
2nd hole set
Bottom hole
Middle hole
Top hole
JAMB BRACKET SCHEDULE
DOOR HEIGHT
TRACK
LENGTH
6’0”
64” (1626
mm)
9
M
11
M
NA
6’3”
67” (1702
mm)
9
B
11
M
NA
6’6”
70” (1778
mm)
9
M
10
B
NA
6’9”
73” (1854
mm)
9
M
10
B
NA
7’0”
76” (1930
mm)
9
M
10
B
NA
7’6”
82” (2083
mm)
9
T
10
M
11
M
7’9”
85” (2159
mm)
9
T
10
M
11
M
8’0”
88”
(2236mm)
9
T
10
M
11
M
Stud
plate
3
Tools Required: None
1st hole set
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.
4
Tools Required: None
Quick Install
vertical
track
Quick Install Jamb Brackets
NOTE: If you have Fully Adjustable Flag Angles, 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.
Vertical track
Top of track
Lower
Quick
Install tab
Quick
Install
feature
Flag angle
1/4”-20
Flange hex nuts
Quick Install tabs
in place
1/4”- 20 x 9/16”
Track bolts
Horizontal Track Angles
Tools Required: Hammer
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.
1ST SET
2ND SET
3RD SET
B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE
5
Fully Adjustable Jamb Brackets
Tools Required: None
NOTE: If you have Quick Install jamb brackets, Riveted Track or Angle Mount Track, skip this
step.
6
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
Lower hole of
hole/ slot pattern
1/4”- 20
Flange hex nut
6
Cotter pin (attached into
place from opposite
side of bottom bracket)
Washer
Short stem track roller
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Saw horses
NOTE: Refer to Package Contents / Parts Breakdown, to determine which bottom corner
brackets you have.
Uncoil the counterbalance lift cables. Depending on which bottom corner brackets you have
(reference illustrations below), slip the loop at the ends of the counterbalance lift cable over
the milford pin of the bottom corner bracket or secure the cable loop to the clevis pin and
bottom corner bracket using a 5/16” flat washer and a cotter pin. Repeat for other bottom
corner bracket.
Warning
WARNING
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.
Starting on the left hand side, attach the 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 1/4” - 20
x 11/16” self drilling screws and (1) 1/4” - 14 x 5/8” tamper resistant self drilling screw.
Repeat for right hand bottom corner bracket.
NOTE: All doors are provided with the tamper resistant fastener for the bottom corner
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 11/16” self drilling screw in its place.
NOTE: Check to ensure cable loop fits tightly over the milford pins.
Insert a short stem track roller with roller spacer into the bottom corner bracket. Repeat for
other side.
NOTE: Verify bottom weather seal (bottom seal) is aligned with door section. If there is more
than 1/2” excess bottom weather seal on either side, trim bottom weather seal even with
door section.
Bottom
weather seal
Counterbalance
lift cable loop
7
tion
sec
Tools Required: Power drill, 7/16” Socket driver, Saw horses
Center stile(s)
End stile
(2) 1/4” - 14 x 7/8”
Self drilling screws
Bottom corner
bracket
Roller spacer
1/4”-14 x 5/8”
Tamper resistant
self drilling screw
Graduated Hinge Attachment
End stile
B
Milford pin
Short stem track roller
Bottom corner
bracket
Roller spacer
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.
NOTE: The #5 graduated end hinges serves as end hinges on the Intermediate III section.
NOTE: The #6 graduated end hinges serves as end hinges on the Intermediate IV section.
NOTE: The #7 graduated end hinges serves as end hinges on the Intermediate V section.
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
#1Center hinge(s)
track roller
#1 Graduated
end hinge
#2 Graduated end hinge
(short stem track roller
Lower
inserted into tube
hinge leaf
furthest from section)
1/4”-14 x 5/8” Self tapping
screw locations
Counterbalance Lift Cables and Rollers
m
otto
(4) 1/4”-20 x 11/16”
Self drilling screws
Clevis pin (inserted through
cotter pin and bent into place)
Jamb bracket
in place
End cap
Bottom weather
seal
Counterbalance
cable loop
1/4”- 20 x
9/16”
Track bolt
Bottom
section
End cap
3rd hole set
F.A. jamb
bracket
Counterbalance
lift cable
(1) 1/4” - 20 x 5/8”
Tamper resistant screw
8
Top Fixtures (A)
Tools Required: Power drill, 7/16” Socket driver, Saw horses
NOTE: Using the illustrations below and referring to Package Contents / Parts Breakdown, to
determine if you have Top Fixture Bases and Top Fixture Slides or not. If you have Top Fixture
Assemblies, skip this step.
7
Starting on the left hand side, align the top fixture base on top of the corner of the top section
and even with the edge of the section. Fasten to section through end cap using (4) 1/4” - 20
x 11/16” self drilling screws. Loosely secure the top fixture slide to the top fixture base using
(1) 5/16” - 18 x 3/4” carriage bolt and (1) 5/16” - 18 hex nut. The top fixture assembly will
be tightened and adjusted later, in step, Adjusting Top Fixtures. Insert short stem track roller
into top fixture slide. Repeat for other side.
Strutting Schedule - Models 8200
Door Heights
Section Types
n
Top
tio
sec
Top
Top fixture base
(4) 1/4”-20 x 11/16”
Self drilling screws
Intermediate I
5/16”-18 x 3/4”
Carriage bolt
Roller
7’6” - 8’0” (4)
Top fixture slide
Lock
5/16”-18 Hex nut
Bottom
End cap
Door Configurations
Door Widths
14’0” - 16’0” 17’0” - 18’0”
20’0”
Solid
2” Strut
2” Strut
3” Strut
Windows
3” Strut
3” Strut
3” Strut
Solid
N/A
N/A
3” Strut
Windows
N/A
N/A
3” Strut
Solid
N/A
2” Strut
3” Strut
Windows
N/A
2” Strut
3” Strut
Solid
2” Strut
2” Strut
3” Strut
Windows
2” Strut
2” Strut
3” Strut
Strutting Schedule - Models 8000, 8100 and 8200
9
Strut (U-shaped)
Tools Required: Power drill, 7/16” Socket driver, Tape measure, Saw horses
Door Heights
NOTE: Refer to door section identification, located in the pre-installation section of this
manual to determine what size sections you need to use as your lock (second) section, intermediate (third) section, intermediate (fourth) section, intermediate (fifth) section, intermediate
(sixth) section, intermediate (seventh) section and top section. Measure your sections to
make sure they are the correct height as indicated on the chart.
NOTE: Refer to the strutting schedules below to determine the placement of strut(s) on your
door. Be sure to use the proper schedules for the type of door model and the size of your
door.
Using sawhorses, lay sections together on a flat smooth surface. Ensure the hinges are on
top of their corresponding sections. Referring to the strutting schedule, determine how many
struts your door needs and on what sections they are needed to be installed.
NOTE: Sections not noted in the strutting schedule, do not require a strut.
NOTE: All strut(s) are placed at the top of the section(s).
INSTALLATION ON ALL SECTIONS (EXCEPT TOP SECTION): Place the strut on the section
up against the bottom of the hinges. Center the strut side to side on the section, as shown.
Secure the strut to the section using (2) 1/4” - 20 x 7/8” self drilling screws at each end
hinge location and (2) 1/4” - 20 x 7/8” self drilling screws at each center hinge location.
INSTALLATION ON TOP SECTION: Place the strut on the top edge of the top section, as
shown. Center the strut side to side on the section. Secure the strut to the section using (2)
1/4” - 20 x 7/8” self drilling screws at each end hinge location and (2) 1/4” - 20 x 7/8” self
drilling screws at each center hinge location.
Section Types
Top
Intermediate II
7’6” - 8’0” (5)
Intermediate I
Lock
Bottom
Top
Intermediate II
8’3” - 8’9” (5)
Intermediate I
Strutting Schedule - Models 8000 and 8100
Lock
Door Heights
Section Types
Top
Intermediate I
7’6” - 8’0” (4)
Lock
Bottom
Door Configurations
Door Widths
14’0” - 16’0” 17’0” - 18’0”
Bottom
20’0”
Solid
2” Strut
2” Strut
3” Strut
Windows
3” Strut
3” Strut
3” Strut
Solid
N/A
N/A
3” Strut
Windows
N/A
N/A
3” Strut
Solid
N/A
2” Strut
3” Strut
Windows
N/A
2” Strut
3” Strut
Solid
N/A
2” Strut
3” Strut
Windows
N/A
2” Strut
3” Strut
Top
Intermediate III
Intermediate II
9’0” - 10’6” (6)
Intermediate I
Lock
Bottom
8
Door Configurations
Door Widths
14’0” - 16’0” 17’0” - 18’0”
20’0”
Solid
2” Strut
3” Strut
Windows
3” Strut
3” Strut
Solid
N/A
3” Strut
Windows
N/A
3” Strut
Solid
N/A
2” Strut
3” Strut
Windows
N/A
2” Strut
3” Strut
Solid
N/A
3” Strut
Windows
N/A
3” Strut
Solid
2” Strut
3” Strut
Windows
2” Strut
3” Strut
Solid
2” Strut
N/A
Windows
3” Strut
N/A
Solid
N/A
N/A
Windows
N/A
N/A
Solid
N/A
2” Strut
N/A
Windows
N/A
2” Strut
N/A
Solid
N/A
N/A
Windows
N/A
N/A
Solid
2” Strut
N/A
Windows
2” Strut
N/A
Solid
2” Strut
N/A
Windows
3” Strut
N/A
Solid
2” Strut
N/A
Windows
2” Strut
N/A
Solid
2” Strut
N/A
Windows
2” Strut
N/A
Solid
2” Strut
N/A
Windows
2” Strut
N/A
Solid
N/A
2” Strut
N/A
Windows
N/A
2” Strut
N/A
Solid
2” Strut
N/A
Windows
2” Strut
N/A
Top section
Strutting Schedule - Models 8000, 8100 and 8200
Door Heights
Section Types
Solid
Top
Intermediate IV
Intermediate III
10’9” - 12’3” (7)
Door Configurations
Intermediate II
Intermediate I
Lock
Bottom
Top
Intermediate V
Intermediate IV
Intermediate III
12’6” - 14’0” (8)
Intermediate II
Intermediate I
Lock
Bottom
20’0”
N/A
N/A
Windows
3” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
N/A
N/A
N/A
Windows
N/A
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
3” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
Solid
N/A
N/A
N/A
Windows
N/A
N/A
N/A
Solid
2” Strut
N/A
N/A
Windows
2” Strut
N/A
N/A
End hinges
Top fixture slide
(4) 1/4”-20 x 11/16”
Self drilling screws
(2) 1/4”-20
Flange hex nuts
Short stem track roller
11
Step Plate
Tools Required: Tape measure, Power drill, Drill bits, 7/16” Wrench, Phillips head
screwdriver, Saw horses
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
Bottom
section
section
outside
inside
Inside
step
plate
6” Max.
mounting
height
(2) 1/4”-20 x 2 3/4”
Carriage bolts
(2) 1/4”-20 Nuts
(2) 5/16” Dia.
drilled holes
Outside
step plate
(2) 1/4”-20 x 2 3/4”
Carriage bolts
Inside
step
plate
Bottom
section inside
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.
Outside of
Inside of
Center stile
bottom
bottom
(2) 7/32”
section
section
Diameter holes
Inside
step
Outside
plate
step plate
Center hinge(s)
1/4”-20 x 7/8” Self drilling
screws
Strut
Typical
Typical lower
upper
hinge
leaf
Top fixture hinge
(If applicable) leaf
Strut installation at
Strut installation for other sections
top of top section
10
End cap
Upper center
slotted hole
Top fixture
base
1/4”-20 x 7/8” Self drilling
screws
Strut installation
for other sections
14’0” - 16’0” 17’0” - 18’0”
Hole
2” Strut
Strut installation
for top section
Strut
Door Widths
Top Fixtures (B)
Tools Required: Power drill, 7/16” Socket driver, Saw horses
(2) #8 x 1-5/8” Self
tapping screws
NOTE: Using the illustrations below and referring to Package Contents / Parts Breakdown, to
determine if you have Top Fixture Assemblies or not. If you have Top Fixture Bases and Top
Fixture Slides, skip this step.
Starting on the left hand side, align the upper-center hole of top fixture base with the hole
in the end stile of the top section or below strut (if applicable) and even with the edge of the
top section, as shown. The slotted half of the top fixture base should be facing upwards.
Fasten to section using (4) 1/4” - 20 x 11/16” self drilling screws. The top fixture slide will be
tightened and adjusted later, in step, Adjusting Top Fixture. Insert short stem track roller into
top fixture slide. Repeat same process for other right hand 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 1/4” - 20 flange hex nuts.
12
(2) 7/16”
Diameter holes
Lift Handle
Tools Required: Tape measure, Pencil, Power drill, 9/32”/1/2” Drill bits, 1/4”
Wrench, Saw horses
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
9
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.
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.
Center
(2) 9/32”
Outside
Inside lift
(2) Spacers
stile
Diameter holes
lift handle
handle
(2) 1/4” x 2-1/2”
Inside
Outside
Carriage bolts
of lock
of lock
section
section
(2) 1/4”-20
Hex Nuts
4”
Flag
angle
(2) 1/2”
Diameter holes
Vertical
track
assembly
Outside lift
handle
Jamb
bracket
Outside of
lock section
20” Minimum to
30” Maximum
Outside
step plate
13
5/16” x 1-5/8”
Lag screws
Bottom
section
Outside of
bottom
section
12R FA 15R FA 12R QI 15R QI
Flag angle lag screw locations
3/8” to 5/8”
Spacing
Track
rollers
Bottom section
Vertical track
Floor
Track roller
For Riveted Vertical Track Assembly: 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 as shown between the bottom section and
vertical track. Hang counterbalance lift cable over flag angle. Repeat same process for other
side.
For Angle Mount Vertical Track Assembly: Loosely fasten the slots in the wall
angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom
slot in the wall angle, maintain 3/8” to 5/8” spacing as shown between the bottom section
and vertical track. Hang counterbalance lift cable over angle mount. Repeat same process for
other side.
Bottom Section
Tools Required: Level, Wooden shims (if necessary)
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.
Angle mount
vertical track
assembly
Riveted
vertical track
assembly
Weather seal
Wall
angle
Level
Vertical
track
5/16” x 1-5/8”
Lag screws
Bottom section
Bottom
section
Wooden shims
(If necessary)
14
Flag
angle
Jamb
bracket
Slot
Bottom section
5/16” x 1-5/8” Vertical
Lag screws
track
Vertical Tracks
Flag angle lag screw
locations
3/8” to 5/8”
Spacing
Bottom section
Vertical track
Floor
Tools Required: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure,
Level, Step ladder
NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable
Flag Angles, Riveted Vertical Track Assemblies or you may have Angle Mount 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 track assemblies must be level from side
to side. If the bottom section was shimmed to level it, the vertical track assembly on the shimmed side must be raised the height of the shim.
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 or Fully Adjustable Flag Angles: Loosely
fasten jamb brackets and flag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag
15
Stacking Sections
Tools Required: Power drill, 7/16” Socket driver
NOTE: Refer to door section identification, located in the pre-installation section of this
manual to determine what size sections you need to use as your lock (second) section, intermediate (third) section, intermediate (fourth) section, intermediate (fifth) section, intermediate
(sixth) section and intermediate (seventh) section. Measure your sections to make sure they
are the correct height as indicated on the chart.
NOTE: Make sure graduated end and center hinges are flipped down, when stacking another
section on top.
Place short stem 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 5/8” self-tapping screws.
10
Repeat same process for other sections, except top section.
Important: Push & hold the hinge leafs securely against the sections while
securing with 1/4” - 20 x 5/8” self-tapping 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.
Horizontal Tracks
17
Tools Required: Ratchet wrench, 9/16” Socket, 9/16” Wrench, level, Step ladder
NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable
Flag Angles, Riveted Vertical Track Assemblies or you may have Angle Mount Vertical Track
Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Flag Angles /
Vertical Track Assemblies you have.
Warning
WARNING
Do not raise door until horizontal tracks are secured at
rear, as outlined in Step, Rear Back Hangs, or door could fall
from overhead position causing severe or fatal injury.
Lock section
If you have Quick Install Flag Angles: To install horizontal track, place the curved
end over the top track roller of the top section. Align key slot of the horizontal track with the
Quick Install tab of the flag angle. Push curved portion of horizontal track down to lock in
place.
Vertical
tracks
Flag angle
3/8”-16
Hex nut
Flag angle
Horizontal
track
Quick
Install tab
1/4”-20 x 11/16” Self drilling screw locations
Quick
Install tab
in place
Horizontal track
angle
Tracks flush
Key slot
Center
hinge(s)
Left graduated end hinge
with short stem track roller
16
Right graduated end hinge
with short stem track roller
3/8”-16 x 3/4”
Truss head bolt
Top Section
If you have Fully Adjustable Flag Angles: To install horizontal track, place the
curved end over the top track roller of the top section. Align the bottom of the horizontal
track with the top of the vertical track. If you have Quick Install horizontal track, tighten the
horizontal track to the flag angle with a stud plate and (2) 1/4” - 20 flange hex nuts. If you
have Universal horizontal track, tighten the horizontal track to the flag angle with (2) 1/4” - 20
x 9/16” track bolts and (2) 1/4” - 20 flange hex nuts.
Quick Install
Fully Adjustable
3/8”-16
horizontal
horizontal track
Hex nut
track
Tools Required: 7/16” Wrench, Hammer, Step ladder, Tape measure
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 or wall 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 operation.
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.
For Angle Mount Track: Complete the vertical track installation by securing the jamb
bracket(s) and or 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 vertical
track, as shown. Repeat for other side.
1/4”-20
Flange hex nuts
Flag angle
upper slot
1/4”-20
Flange hex nuts
Flag angle
upper slot
Stud
plate
1/4”-20 x 9/16”
Track bolts
3/8”-16 x 3/4”
Truss head bolt
If you have Riveted Track Assemblies or Angle Mount Vertical Track
Assemblies: To install horizontal track, place the curved end over the top roller of the top
section. Align the bottom of the horizontal track with the top of the vertical track. Tighten the
horizontal track to the Flag Angle / Angle Mount with (2) 1/4” - 20 x 9/16” track bolts and (2)
1/4” - 20 flange hex nuts.
3/8”-16 x 3/4”
Rivited flag angle
Horizontal
Truss head bolt
track
3/8”-16
Horizontal
1/4”-20
Hex nut
track angle
Flange hex nuts
Door width
+ 3-3/8” to 3-1/2”
Top of flag angle or
Top of wallangle assembly
Nail
Horizontal
track
Rivited flag
angle
upper slot
Top section
1-11/16”
to 1-3/4”
1/4”-20 x 9/16”
Track bolts
Horizontal
track
Flag
angle
Top
section
Horizontal
track angle
Flag angle or
wallangle assembly
1/4”-20
Flange hex
nuts
Angle
mount
1/4”-20
Flange hex
nuts
Flag angle
Vertical track
against track rollers
1/4”-20 x 9/16”
Track bolts
3/8”-16
Hex nut
Horizontal
track angle
Horizontal
track
1/4”-20 x 9/16” 3/8”-16 x 3/4”
Truss head bolt
Track bolts
Next level the horizontal track assembly and bolt the horizontal track angle to the first
11
Angle
mount
encountered slot in the flag angle / angle mount using (1) 3/8” - 16 x 3/4” truss head bolt
and (1) 3/8” - 16 hex nut. Repeat for other side. Next remove the nail that was temporarily
holding the top section in place, installed in step, Top Section.
IMPORTANT: Failure to remove nail before attempting to raise door could
cause permanent damage to top section.
Left end
bracket
(2) 3/8”-16
Hex nuts
Adjusting Top Fixtures
18
Upper
slot
Tools Required: 7/16” Wrench, Step ladder
Top s
e
ction
Top fixture slide
n
ectio
s
Top
Top
fixture
slide
Horizontal
track
5/16”-18
Hex nut
Short stem
track roller
19
End Bearing Brackets
Center Bracket
Tools Required: Step ladder, Power drill, 7/16” Socket driver, 3/16” Drill bit, 1/4”
Torx bit, Level, Tape measure, Pencil
Tools Required: Step ladder, Power drill, 3/16” Drill bit, Ratchet wrench, 7/16”
Socket driver, 9/16” Socket, 9/16” Wrench
Left end bracket
(2) 3/8”-16 x 3/4”
Truss head bolts
Upper slots
Lower slots
Typicall center
bracket
Mounting surface
NOTE: Refer to Package Contents / Parts Breakdown, to determine which End Bearing
Brackets you have.
NOTE: Prior to fastening end bearing brackets into the door jamb, pilot drill using a 3/16”
drill bit.
IMPORTANT: Right and left hand is always determined from inside the building
looking out.
NOTE: Depending on your door’s configuration you may have to break the end bearing
brackets apart.
NOTE: End bearing brackets are right and left hand.
Attach the left hand end bearing bracket through either the end bearing bracket’s upper or
lower slots to the left hand horizontal track angle using (2) 3/8” - 16 x 3/4” truss head bolts
and (2) 3/8” - 16 nuts.
IMPORTANT: The end bearing bracket’s lower slots are used on doors with
12” radius track; the upper slots are used on doors with 15” radius track.
Secure the top of the end bearing bracket to the jamb using 5/16” x 1-5/8” lag screw(s).
Repeat the same process for right hand side.
(2) 3/8”-16
Hex nuts
20
NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s)
came with your door.
NOTE: Prior to fastening center bracket(s) into the door jamb, pilot drill using a 3/16” drill bit.
NOTE: Refer to Package Contents / Parts Breakdown, to determine if your door came with a
coupler assembly. If your door came with a coupler assembly, the mounting surface needs to
be a minimum of 17” wide. The two center bearing brackets will need to be spaced 12” to
14” apart at the center of the door, as shown.
NOTE: If your door came with (4) springs, each of the outer springs mounting surface will
need to be a minimum of 3” wide.
NOTE: If needed, measure the diameter of your springs. If you have a one piece shaft with
3-3/4” diameter springs, they do not share center brackets and do not have a coupler assembly.
First, locate the center of the door. Mark a vertical pencil line on the mounting surface above
the door, at the center. Measure from the center of the bearing, in one of the end bearing
brackets, downwards, to the top the door. Using that measurement, measure that distance
upwards from the top of the door to the mounting surface and mark a horizontal pencil line
which intersects the vertical pencil line.
1/4”-20
Flange hex nut
Horizontal track
Horizontal
track angle
Lower slots
NOTE: Depending on your door, you may have Top Fixture Bases and Top Fixture Slides or
you may have Top Fixture Assemblies. Refer to Package Contents / Parts Breakdown, to
determine which Top Fixtures you have.
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 or the (1) 5/16” - 18 hex nut to secure the top fixture slide to the top fixture base.
Repeat for other side.
Short stem track
roller
(3) 5/16” x 1-5/8”
Lag screws
(2) 3/8”-16 x 3/4”
Truss head bolts
Vertical line
Horizontal line
tal
Typicall center
of end bearing
bracket
tion
op
)
line
to h
o
of d
sta
l di
a
Equ
(t
nce
ec
or s
on
oriz
If your door did not come with a center coupler assembly or Torsion
Springs less than 3-3/4” ID: Mark a vertical pencil line on the mounting surface above
the door, at the center. Align the edge of the center bracket with the vertical pencil line and
the center of the center bracket with the horizontal pencil line; this is to ensure the torsion
shaft is level between the center and end bearing brackets.
NOTE: On some single spring doors, the single spring can be longer than half the opening
width. If your spring is longer, then the center bracket must be mounted off center for the
spring to fit properly. Measure spring length to determine appropriate center bracket location.
(1) 5/16” x 1-5/8”
Lag screw
Horizontal track angle
Bend back and fourth to
seperate the (2) end
bearing brackets
12
Center bracket
bushing assembly
(2) 5/16” x 1-5/8”
Lag screws
Mounting
surface
(3” Minimum)
Vertical
line
Mounting surface
(3” Minimum)
Vertical
line
(2) 5/16” x 1-5/8”
Lag screws
Horizontal
line
Torsion shaft
Horizontal
line
(1) 5/16” X 2” or (1) 5/16” x 1-5/8” Tamper-resistant lag screw
Center
bearing
bracket
assembly
Left hand cable
drum, red
Right hand
wound, red
winding cone
(left hand side)
If your door did come with a center coupler assembly or 3-3/4” ID Torsion Springs: Mark a vertical pencil line on the mounting surface above the door, at the
center. Split the difference up and position the (2) center bearing brackets apart from each
other. Mark two vertical pencil lines, one for each center bearing bracket onto the mounting
surface above the door.
NOTE: If your door came with a center coupler assembly or if it utilizes 3-3/4” springs, the
springs will not share a center bracket.
NOTE: If your door has (4) springs, split the distance between the center of the door and the
end bracket on each side to locate the intermediate center brackets.
Attach each of the center bracket(s) to the mounting surface, using (2) 5/16” x 1-5/8” lag
screws and (1) 5/16” x 2” tamper-resistant lag screw.
IMPORTANT: Use a 5/16” x 1-5/8” tamper-resistant lag screw instead of the
5/16” x 2” tamper-resistant lag screw if mounting surface is mounted over
masonry. Tamper-resistant lag screw must be attached through the bottom
hole of the center bracket(s).
†
Center
Vertical line
Mounting surface
of
(17” Minimum)
door
Vertical
line
(2) 5/16” x 1-5/8”
Lag screws
(2) 5/16” x 1-5/8”
Lag screws
Horizontal
line
21
Right hand
cable drum,
black
(1) 5/16” X 2” or (1) 5/16”
x 1-5/8” Tamper-resistant
lag screw
Left hand wound,
black winding cone
(right hand side)
IMPORTANT: ON SINGLE
Center bearing
SPRING APPLICATIONS,
ONLY A LEFT HAND WOUND
(BLACK WINDING CONE),
WHICH GOES ON THE RIGHT
HAND SIDE IS REQUIRED.
With assistance, pick up the torsion spring assembly and slide one end of the torsion shaft
/ torsion keyed shaft through one end bearing bracket. Lay the middle of the torsion shaft /
torsion keyed shaft into the center bracket. Slide the other end of the torsion shaft / torsion
keyed shaft into the other end bearing bracket. Position the torsion shaft / torsion keyed shaft
so that equal amounts of the shaft extend from each end bearing bracket.
Equal spacing
Center
bracket
bushing
Left hand end
bearing bracket
Torsion shaft
Right hand end
bearing bracket
Center bracket
If you have a Coupler Assembly:
Disassemble the coupler assembly by removing the (3) 3/8” - 16 x 1-3/4” hex head screws
and the (3) 3/8”-16 nylon hex lock nuts from the coupler halves. Loosen the set screws.
Set the components aside. Facing the inside of the door, lay the (2) torsion keyed shafts on
the floor. One torsion keyed shaft on the left hand side and the other torsion keyed shaft on
the right hand side. Starting on the left hand side, lay one of the coupler halves, the center
bearing, torsion spring with the red winding cone and the red cable drum at the left end of
the torsion keyed shaft. Next on the right hand side, lay the other coupler half, center bearing,
the torsion spring with the black winding cone, and the black cable drum at the right end of
the torsion keyed shaft.
Slide the coupler halves, center bearings onto the torsion keyed shafts followed by the torsion
springs and the cable drums, as shown.
IMPORTANT: The coupler halves, center bearings, torsion springs, cable
drums must be positioned, as shown.
Slide the flat edge of the couple half flush with the side edge of the torsion keyed shaft. Insert
(1) key into the slot of both the coupler half and the slot in the torsion keyed shaft. Tighten
the (2) set screws and the locking nut to secure the coupler half to the torsion keyed shaft,
as shown.
NOTE: Tighten the set screws to 14-15 ft. lbs. of torque (once set screws contact the shaft,
tighten set screws one full turn). Repeat the same process for the other coupler half.
† (2) Center bearing
brackets spaced 6” to 7”
apart from the center of
the door.
Torsion Spring Assembly
Tools Required: 3/8” Wrench, 9/16” Wrench, Step Ladder
NOTE: Refer to the Package Contents and or Parts Breakdown to determine if your door
came with a coupler assembly.
IMPORTANT: Right and left hand is always determined from inside the building
looking out.
IMPORTANT: Identify the torsion 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.
IMPORTANT: On single spring applications, only a left hand wound (black
winding cone), which goes on the RIGHT HAND SIDE is required.
NOTE: The set screws used on all torsion winding cones and cable drums are now colored
red. DO NOT identify right and left hand by the set screw color.
If you don’t have a Coupler Assembly:
Facing the inside of the door, lay the torsion shaft / torsion keyed shaft on the floor. Lay the
torsion spring with the black winding cone and the black cable drum at the right end of the
torsion shaft / torsion keyed shaft. Lay the torsion spring with the red winding cone and the
red cable drum at the left end of the torsion shaft / torsion keyed shaft.
Slide the center bracket bearing / center bracket bushing onto the torsion shaft / torsion
keyed shaft followed by the torsion springs and cable drums.
IMPORTANT: The center bracket bearing / center bracket bushing, torsion
springs, and cable drums must be positioned, as shown.
Black cable drum
(right hand side)
Coupler
halves
Set screws
and Lock
nut
Center
coupler
assembly
(3) 3/8” - 16 x 1-3/4” Hex head screws
and (3) 3/8” - 16 Nylon hex lock nut
Torsion
keyed
shaft
Coupler
halves
Red cable drum
(left hand side)
Set screws
and Lock nut
Center
bearing
Right hand wound, Key
red winding cone
(left hand side)
Torsion keyed shaft
13
Center
bearing
Left hand wound,
black winding cone
(right hand side)
Key
Coupler halves
assembled
Center
coupler
assembly
NOTE: Ensure both torsion keyed shafts have equal amounts of the shafts extending from
each end bearing bracket.
Black cable drum
(right hand side)
Torsion keyed shaft
Coupler
halves
Set screws
and Lock
nut
Stationary
spring cone
Center
bearing
(3) 3/8” - 16 x 1-3/4” Hex head screws
and (3) 3/8” - 16 Nylon hex lock nut
Red cable drum
(left hand side)
Center bearing
Left hand wound,
black winding cone
(right hand side)
Stationary
spring cone
Key
Center
bearing
Right hand wound,
red winding cone
(left hand side)
Torsion
spring
Set screws
and Lock nut
Coupler halves
assembled
(2) 3/8”-16 Nuts
With assistance and starting on the left hand side of door, pick up the left hand torsion spring
assembly and slide one end of the torsion keyed shaft through the end bearing bracket. Lay
the other side of the torsion keyed shaft into the center bracket. Repeat the same process
for the right hand torsion spring assembly. Position both torsion keyed shafts so that equal
amounts of the shafts extend from each end bearing brackets.
Center bearing
Equal spacing
brackets
Center
bearing
Torsion
keyed
shaft
Right
hand end
bearing
bracket
Stationary
spring cone
Center bracket
Torsion
spring
Equal spacing
Center
bracket
bushing
Right hand end
bearing bracket
22
Torsion
spring
(2) 3/8”-16 x 1-1/2”
Hex head bolts
(3) 3/8” - 16 x 1-3/4”
hex head screws and
(3) 3/8” - 16 Hex nuts
Left hand end
bearing bracket
Torsion keyed shafts
Typical center bracket
assembly
Coupler
half
Right hand wound,
red winding cone
(left hand side)
Left hand end
bearing bracket
Spring
warning tags
Torsion
spring
Stationary spring cone
Equal
spacing
Typical center
bracket bushing
Key
Torsion keyed shaft
Torsion
keyed
shaft
Torsion spring
Typical center bracket
Coupler
halves
Center bracket
23
Torsion
spring
Coupler
assembly
Coupler halves
(2) 3/8”-16 x 1-1/2”
Hex head bolts and (2)
3/8”-16 Hex nuts
Center
bracket
Counterbalance Lift Cables
Tools Required: Step Ladder, Locking Pliers, 3/8” Wrench
Starting on the left hand side, thread the counterbalance lift cable up and around the front
side of the left hand cable drum.
IMPORTANT: Verify that there are no counterbalance lift cable obstructions.
NOTE: Always assemble the left hand cable and cable drum first to help maintain equal cable
tension on both sides of the door.
Hook the counterbalance lift cable into the left hand cable drum. Slide the left hand cable
drum up against the left hand end bearing bracket. Counterbalance lift cable should
terminate at the 3 o’clock position. Tighten the (2) set screws in the drum to 14-15 ft. lbs. of
torque (once set screws contact the shaft, tighten screws one full turn).
NOTE: If you have torsion keyed shaft(s), insert (1) key into the slot of both the cable drum
and the slot in the torsion keyed shaft, as shown.
Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach
locking pliers to the torsion shaft and brace locking pliers up against jamb to keep counterbalance lift cable taut. Repeat for right hand side.
IMPORTANT: Inspect each counterbalance lift cable making sure they are
seated properly onto the cable drums and that both counterbalance lift
cables have equal tension.
Once the counterbalance cables are set and if applicable tighten the coupler assembly
together by tightening the (3) 3/8” - 16 nylon hex lock nuts to secure the coupler halves
together.
Torsion Spring Attachment
Tools Required: Step Ladder, Ratchet Wrench, 9/16” Socket, 9/16” Wrench
NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s)
came with your door.
NOTE: Refer to Package Contents / Parts Breakdown, to determine if your door came with a
coupler assembly.
IMPORTANT: The spring warning tag(s) supplied must be securely attached
to the stationary spring cone(s) in plain view. Should a replacement spring
warning tag be required, contact Wayne-Dalton for free replacements.
NOTE: Measure the diameter of your springs. If your spring diameter is 3-3/4”, the springs
do not share center brackets. If your spring diameter is either 2” or 2-5/8”, then two springs
will share the same center bracket, unless a coupler assembly is provided.
If you don’t have a Coupler Assembly:
Slide center bracket bushing into the spring. Align the stationary spring cone(s) with the holes
in the center bracket bushing assembly. Secure the torsion spring(s) to the center bracket
bushing assembly with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts.
If you have a Coupler Assembly:
Slide center bracket bushing into the spring. Align the stationary spring cone with the holes in
the center bracket. Secure the torsion spring to the center bracket with (2) 3/8”-16 x 1-1/2”
hex head bolts and (2) 3/8” - 16 nuts. Repeat the same process for the other center bearing
bracket.
At the middle of the two center bearing brackets, re-assemble the coupler assembly by
loosely fastening the coupler halves together using the (3) 3/8” - 16 x 1-3/4” hex head
screws and the (3) 3/8” - 16 nylon hex lock nuts, as shown.
14
Typicall left hand
cable drum
Typicall left hand end
bearing bracket
tracks just above a track roller assembly. This is to prevent the garage door from rising while
winding torsion counterbalance spring(s).
Torsion shaft /
Torsion keyed shaft
Warning
WARNING
Failure to ensure door is in a closed position and to place
vice clamp onto vertical track can allow door to raise and
cause severe or fatal injury.
Winding Bars
(Steel Rods)
Counterbalance
lift cable
Size Of Winding Bar
(Inches)
1/2” dia. x 18”
5/8” dia. x 24”
Spring Diameter
Used On
2” and 2-5/8”
3-3/4”
C-Clamps
Counterbalance lift cable hooked in cable
drum
Typical sections
Jamb
Vice clamps above third
track roller on both sides of
door
Locking pliers
Typicall left
hand end
bearing bracket
Counterbalance lift cable
Typicall left hand
cable drum
Chalking Torsion Spring(s)
Warning
WARNING
Tools Required: Step Ladder, Chalk
Use only specified winding bars, as stated in Step Securing
Door for Spring Winding. DO NOT SUBSTITUTE with screwdrivers, pipe, etc. Other tools may fail or release from the spring
cone and cause serious personal injury.
Draw a chalk line horizontally along the center of the torsion spring coil(s). As the torsion
spring is wound, the chalk line will create a spiral. This spiral can be used to count and
determine the number of turns that are applied on the torsion spring.
Original horizontal chalk line, prior
to winding
Torsion
shaft
Center
bracket
Torsion
spring coils
Warning
WARNING
Prior to winding or making adjustments to the springs, ensure you’re winding in the proper direction as stated in the
Installation Instructions. Otherwise the spring fittings may
release from spring if not wound in the proper direction and
could result in severe or fatal injury.
Winding
cone
Spirals created after winding
25
Tools Required: Step Ladder, Approved winding bars, 3/8” Wrench, Leather
gloves, Safety glasses
Winding torsion spring(s) is an extremely dangerous procedure and should be performed only by a trained door system
technician using proper tools and instructions.
Torsion shaft /
Torsion keyed shaft(s)
24
26
Winding Spring(s)
Warning
WARNING
Set screws
Bottom section
Vice clamps / C-Clamps attached to inner
and outer rail of vertical track
Key
Position a ladder slightly to the side of the spring so that the winding cone is easily accessible, and so your body is not directly in 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.
Securing Door for Spring Winding
Tools Required: Vice Clamps
With the door in the fully closed position, place vice clamps / c-clamps onto both vertical
tracks just above the third track roller. This is to prevent the garage door from rising while
winding springs.
NOTE: Check the following before attempting to wind torsion spring(s):
a. Counterbalance lift cables are secured at bottom corner brackets.
b. Counterbalance lift cables are routed unobstructed to cable drums.
c. Counterbalance lift cables are correctly installed and wound onto cable lift drums.
d. Counterbalance lift cables are taut and have equal tension on both sides.
e. Cable lift drums are against end bearing brackets and set screws are tight.
f. Torsion spring or springs are installed correctly.
g. Review the label attached to the spring warning tag, to determine number of spring turns
required.
NOTE: Door MUST be closed and locked when winding or making any adjustments to the
torsion spring(s).
Ensure the Door is in a closed position and place vice clamps / c-clamps onto both vertical
Door Height
Approximate Spring Turns
6’0”
6-7/8
6’3”
7-1/8
6’6”
7-1/4
6’8”
7-3/8
6’9”
7-1/2
7’0”
7-5/8
7’3”
7-7/8
7’6”
8
7’9”
8-1/4
8’0”
8-3/4
Alternately inserting the winding rods into the holes of the spring winding cone, rotate the
winding cone upward toward the ceiling, 1/4 turn at a time, until the required number of
15
complete turns for your door height is achieved. As the last 1/8 to 1/4 turn is achieved,
securely hold the winding rod and carefully stretch the torsion spring 1/8” - 1/4”. Next while
still securely holding the winding rod, tighten both set screws in the winding cone to 14-15 ft.
lbs. of torque (once set screws contact the torsion shaft, tighten screws one full turn).
Carefully remove winding rod from winding cone. Repeat for the opposite spring. While
holding the door down to prevent it from raising unexpectedly in the event the spring(s) were
over-wound, carefully remove the locking pliers from the torsion shaft and vertical tracks.
Adjustments to the number of turns stated may be necessary. If door rises off floor under
spring tension alone, reduce spring tension until door rests on the floor. If the door is hard to
rise or drifts down on its own, add spring tension.
Torsion spring(s) should be wound in the direction the end coil points.
Warning
WARNING
Keep horizontal tracks parallel and within 3/4” to 7/8” maximum 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 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.
Torsion
spring(s)
Spring
coils
HIGH SPRING TENSION CAN CAUSE
SERIOUS INJURY OR DEATH.
HIGH SPRING TENSION CAN CAUSE
SERIOUS INJURY OR DEATH.
Approved
winding
rod
Winding
cone
DO NOT adjust, repair or remove springs or parts to
which springs are connected, such as steel brackets, cables, wood blocks, fasteners or other parts of
the counterbalance system.
Warning
WARNING
DO NOT adjust, repair or remove springs or parts to
which springs are connected, such as steel brackets, cables, wood blocks, fasteners or other parts of
the counterbalance system.
Adjustments or repairs must ONLY be made by a
trained door systems technician using proper tools
and instructions.
DO NOT remove, cover or paint over this tag. Product user should inspect this tag periodically for
legibility and should order a replacement tag from
the door manufacturer, as needed.
©Copyright 2010 Overhead Door Corporation
102081 REV2 06/24/2010
Adjustments or repairs must ONLY be made by a
trained door systems technician using proper tools
and instructions.
Prior to winding or making adjustments to the springs, ensure you’re winding in the proper direction as stated in the
Installation Instructions. Otherwise the spring fittings may
release from spring if not wound in the proper direction and
could result in severe or fatal injury.
DO NOT remove, cover or paint over this tag. Product user should inspect this tag periodically for
legibility and should order a replacement tag from
the door manufacturer, as needed.
©Copyright 2010 Overhead Door Corporation
102081 REV2 06/24/2010
Warning
tag(s)
IMPORTANT: CHECK THE WARNING
TAG(S) ATTACHED TO THE SPRING(S)
FOR THE REQUIRED NUMBER OF
COMPLETE TURNS, TO BALANCE
YOUR DOOR.
Approved winding rod
Set screws
Torsion shaft
27
Now, lift door and check its balance. Adjustments to the required number of spring turns
stated may be necessary. If door rises off floor under spring tension alone, reduce spring
tension until door rests on the floor. If the door is hard to rise or drifts down on its own, add
spring tension. A poorly balanced door can cause garage door operator operation problems.
To adjust spring tension, fully close door. Apply vice grips to track above third track roller.
Insert a winding rod into the winding cone. On single spring doors, counterbalance lift
cable tension must be maintained by placing vice grips on torsion shaft before loosening
set screws in the winding cone. Push upward on the winding rod while carefully loosening
the set screws in the winding cone. BE PREPARED TO SUPPORT THE FULL FORCE OF THE
TORSION SPRING ONCE THE SET SCREWS ARE LOOSE. Carefully adjust spring tension 1/4
turn. Retighten both set screws in the winding cone and repeat for the other side. Recheck
door balance. DO NOT ADJUST MORE THAN 1/2 TURN FROM THE RECOMMENDED NUMBER
OF TURNS.
If the door still does not operate easily, lower the door into the closed position, UNWIND THE
SPRING(S) FULLY (Reference the insert “Removing The Old Door / Preparing The Opening”
section on torsion spring removal) and recheck the following the items:
1.) Check the door for level.
2.) Check the torsion shaft for level.
3.) Check the track spacing.
4.) Check the counterbalance cables for equal tension and proper wrap onto the cable
drums.
5.) Check the track for potential obstruction of the track rollers.
6.) Clamp locking pliers onto track and rewind springs.
IMPORTANT: If door still does not operate properly, then contact a trained
door system technician.
Rear Back Hangs
Tools Required: Ratchet wrench, Socket: 1/2” 5/8”, Wrench: 1/2” 5/8”, (2) Vice
clamps, Tape measure, Level, Hammer, Step Ladder
Important: Hold the door down to prevent it from rising unexpectedly in the
event the spring(s) was over-wound and cautiously remove vice clamps from
vertical tracks.
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
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.
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 back hangs for the horizontal tracks.
Attach the horizontal tracks to the rear back hangs with 5/16” - 18 x 1” hex bolts and nuts
(may not be supplied). Horizontal tracks must be level and parallel with door within 3/4” to
7/8” maximum of door edge.
Warning
WARNING
Exceeding the recommended listed door weight limitations of
specific gauge perforated angles may result in door falling
when raised, causing severe or fatal injury.
Warning
WARNING
Verify perforated back hang angle load ratings with back
hang angle supplier.
Perforated Angle Gauge Weight Limitations:
Perforated Angle Gauge
Door Weight
2” x 2” x 12 Gauge
Door Weight Less Than 800 lbs.
1-1/4” x 1-1/4” x 13 Gauge
Door Weight Less Than 305 lbs.
1-1/4” x 1-1/4” x 15 Gauge
Door Weight Less Than 220 lbs.
1-1/4” x 1-1/4” x 16 Gauge
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.
16
3/4” To 7/8”
Horizontal tracks
Vice clamp
Vice clamp
2nd Track roller
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
Horizontal
track
(3) 5/16” Bolts and nuts
5/16”-18 x 1-1/4”
Hex bolt must extend into the
track to serve as a roller stop
Perforated angle
Sound framing
members
(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
Perforated angle bolted
using (2) 5/16” x 1-5/8”
hex head lag screws to
ceiling member and
parallel to door
17
Door edges
Horizontal tracks
3/4” To 7/8”
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 unlocked position if an operator is installed on this door.
Square hole in
vertical track
Second section
(4) 1/4”-20 x 11/16”
Self drilling screws
Side lock
1/8”
End stile
Pull Down Rope
Warning
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
Pull
down
rope
18
Maintenance
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
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.
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.
Caution: Do not paint door. Painting door will void your warranty.
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
Surface preparation for painting
Wax on the surface must be removed or paint peeling/ flaking will result. To remove this
wax, it will be necessary to lightly scuff the surface with a fine steel wool pad saturated with
soapy water. A final wipe and rinse should be done with clean water only to remove any loose
particles and any soapy film residue.
Surface scratches, which have not exposed the metal substrate, can be lightly buffed or
sanded with 0000 steel wool or no. 400 sand paper to create a smoother surface. Care must
be taken to not expose the substrate under the paint. Once the substrate is exposed, the
likelihood for rusting is greatly increased.
If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed
area lightly and paint with a high quality metal primer specifically intended for galvanized
surfaces to protect the area from corrosion. Allow for drying time on primer can label before
applying topcoat.
The surface of the factory-applied finish, that is being painted, must not be too smooth, or
the paint will not adhere to it. It is advisable to test in an inconspicuous area, to evaluate
adhesion. If poor adhesion is observed, surface preparation for painting the factory-applied
finish must be repeated until desired results are achieved. Again, care must be taken to not
expose the substrate under the paint.
Painting
After surface has been properly prepared, it must be allowed to dry thoroughly, and then
coated immediately with premium quality latex house paint. Follow paint label directions
explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate
is exposed and not properly primed, painting with latex paint may cause accelerated rusting
of the steel in the exposed area.
NOTES:
1. Re-painting of finish painted steel doors cannot be warranted, as this condition is totally
beyond the door manufacturer’s control.
2. Consult a professional coatings contractor if in doubt about any of the above directions.
3. Follow directions explicitly on the paint container labels for proper applications of coatings
and disposal of containers. Pay particular attention to acceptable weather and temperature
conditions in which to paint.
Warning
WARNING
GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACKETS, 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 MANUFACTURER’S INSTRUCTIONS.
Warning
WARNING
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
Operation And Maintenance
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.
19
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.
3. Lubrication: The door should open and close smoothly. Ensure the door track rollers
are rotating freely when opening and closing the door. If track rollers do not rotate freely,
clean the door tracks, removing dirt and any foreign substances. Clean and lubricate (use
a non-silicon based lubricant) graduated end hinges, center hinge(s), steel track rollers,
bearings and torsion spring(s) (torsion spring coil surfaces). DO NOT lubricate plastic idler
bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difficult use
a graphite dust to lubricate.
20
Warranty
Limited Warranty
Models 8000, 8100, 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.
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.
•SELLER:
_______________________________________________________________________
•SELLER’S ADDRESS: _______________________________________________________________________
_______________________________________________________________________
21
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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