8000, 8100, 8200 WINDLOAD
Torsion Spring
Installation Instructions and Owner’s Manual
IMPORTANT NOTICE!
Read these instructions carefully before attempting
installation. If in question about any of the proce-
dures, do not perform the work. Instead, have a
trained door systems technician do the installation
or repairs.
Wayne-Dalton Corp.
P.O. Box 67
Mt. Hope, OH 44660
©Copyright 2011 Wayne-Dalton, a Division of Overhead Door Corporation
Part No. 335486
REV4 08/18/2011
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NOTE: DEPENDING ON ThE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT
Package Contents
NECESSARY. REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITh YOUR DOOR.
horizontal angles Rh/Lh
Door sections (as required)
(as required)
(1) Torsion tube
(2) horizontal tracks Rh/Lh
(2) quick Install Rh/Lh
(2) Fully adjustable
flagangles
Rh/Lh flagangles
1
U-Bar’s
(as required)
Top bracket assemblies
(as required)
#1, #2, #3 and #1, #2, #3 and #4
Top bracket assemblies
(as required)
#4 Wide hinges
(as required)
Narrow hinges
(as required)
Weather seal & nails
(if included)
Left and right bottom Extension brackets Long and short stem rollers
q.I. jamb brackets
(as required)
(2) Roller Spacers
brackets (as required)
(as required)
(as required)
(2) Vertical
Rh/Lh tracks
Left and right bottom
brackets (as required)
(1) Center bracket
End bearing bracket (1) Center bracket
bushing
Right & left torsion
springs (as required)
Right and left
counterbalance cables
Pushnuts
(as required)
(2) Step plates
#6 Screw eye and
(2) Lift handles &
spacers
(1) Windload label
Right & left
Drums
Slotted jamb brackets
(as required)
pull rope
(if included)
3
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Package Contents Continued...
(2) 1/4”- 20 hex
1/4”- 20 Flange hex nuts
(as required)
(2) 3/8”- 16
hex nuts
5/16”- 18 hex nuts
(as required)
(2) 3/8” - 16 x 3/4”
Truss head bolts
1/4” - 14 x 7/8” Self drilling
screws (as required)
nuts
5/16” x 1 5/8” hex head lag screws
1/4”- 20 x 9/16” track Bolts
(as required)
Cotter pins
(as required)
Clevis pins
(as required)
(2) 1/4”- 20 X 5/8” Tamper
resistant screws
(as required)
5/16” x 1 5/8” tamper resistant Lag Screw
(as required)
(2) 3/8”- 16 x 1-1/2” hex head
5/16” Washers
(as required)
5/16” x 2” tamper-resistant hex head Lag
Bolts
Screws (as required)
(2) 1/4” x 2- 1/2” carriage bolts
(2) 1/4” x 2-3/4” carriage bolts
Stud plates
(as required)
Door Section Identification
Door Height
Bottom
18”
Lock (second)
Intermediate (third)
Intermediate II (fourth) Top
6’0”
6’6”
7’0”
7’6”
8’0”
18”
18”
21”
18”
18”
18”
18”
21”
18”
18”
NA
18”
21”
21”
18”
21”
21”
NA
18” Or 21”
21”
NA
18”
18”
18”
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.
WARNING LABEL
Unless your door is five sections in height, you will not receive an Intermediate
II section.
The bOTTOM SECTION can be identified by the factory attached bottom
astragal, or by the bottom bracket warning labels on each end stile.
INTERMEDIATE I SECTION
The INTERMEDIATE I SECTION may have a warning label attached to either
right or left hand endstile of the section. This section is always the 3rd section
from the bottom of the door.
BOTTOM BRACkET
WARNING LABELS
ASTRAGAL
BOTTOM SECTION
4
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Tools Required
Pencil
Ratchet wrench
Vice grips
Gloves
Power drill
3/8”, 7/16” Socket driver
Safety glasses
hammer
Phillips head screw-
driver
1/4”, 3/8”, 7/16”, 1/2” &
9/16” Wrenches
9/32”, 1/2”, 3/16” & 1/8” Drill
bits
7/16”, 1/2” & 9/16”
Socket
Level
Tape measure
Vice clamps
Sawhorse
Flat tip screwdriver
1/4” Torx bit
Approved winding bars
Step ladder
Removing An Old Door
IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.
WARNINg
A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INjURY. TO AVOID INjURY hAVE A TRAINED DOOR SYSTEMS TEChNICIAN, USING
PROPER TOOLS AND INSTRUCTIONS, RELEASE ThE SPRING TENSION.
For detailed information see supplemental instructions “Removing an Existing Door /Preparing the Opening”. These instructions are available at no charge from Wayne-
Dalton, a Division of Overhead Door Corporation, P.O. Box 67, Mt. hope, Oh 44660, or at www.Wayne-Dalton.com.
5
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Suitable mounting surface
2” x 6” lumber minimum
header board
2” x 6” lumber
recommended
Preparing the Opening
If you just removed your existing door or you are installing a new door,
complete all steps in PREPARING ThE OPENING.
Tools Needed:
Recommended tools
To ensure secure mounting of track brackets, side and center
bearing brackets, or steel angles to new or retro-fit construction, it is
recommended to follow the procedures outlined in DASMA Technical
from
Door
height
Level header
page 5
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 14” (356 mm) above the
top of the opening for Torsion spring applications. 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).
Plumb jambs
Door
width
IMPORTANT: CLOSELY INSPECT EXISTING jAMBS, hEADER AND
MOUNTING SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE
REPLACED.
headroom
For Torsion spring applications, a suitable mounting surface must
be firmly attached to the wall, above the header at the center
of the opening. The mounting surface must be 2” x 6” lumber
minimum (Select southern yellow pine lumber. Do not use lumber
marked as spruce-pine-fur or SPF). The mounting surface must be
securely attached to the wall with four (4) 3/8” anchors for masonry
constructions or four (4) 5/16” x 4” lag screws for wood construction.
header
jamb
NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting
the lumber. Do not attach the mounting surface with nails.
Weather seal
WARNINg
FAILURE TO SECURELY ATTACh A SUITABLE MOUNTING PAD TO
STRUCTURALLY SOUND FRAMING MEMBER COULD CAUSE SPRINGS TO
VIOLENTLY PULL MOUNTING PAD FROM WALL, RESULTING IN SEVERE
OR FATAL INjURY.
jamb
Weather Seal (May Not be Included):
Cut the weather seal if necessary to fit the header and jambs.
for quick install track: Align the header seal with the inside edge
of the header and temporarily secure it to the header with equally
spaced nails. Next, fit the jamb seals up tight against the header seal
and flush with the inside edge of the jamb. Temporarily secure the
jamb seals with equally space nails. This will keep the bottom section
from falling out of the opening during installation. Equally space nails
approximately 12” to 18” apart.
Weather
seal
Weather
seal
jamb
1/8” to 1/4”
Fully adjustable Track
jamb
quick Install Track
for fully adjustable track: Align the header seal 1/8” to 1/4” inside
the header and temporarily secure it to the header with equally spaced
nails. Next, fit the jamb seals up tight against the header seal and 1/8”
to 1/4” inside the jamb. Temporarily secure the jamb seals with equally
spaced nails. This will keep the bottom section from falling out of the
opening during installation. Equally space nails approximately 12” to
18” apart.
hEADROOM REquIREMENT
TRACk TyPE
Torsion Springs
12” Radius Track
15” Radius Track
12 1/2”
14-1/2”
NOTE: Do not permanently attach weather seal to the jamb at this time.
hEADROOM REquIREMENT: headroom is defined as the space needed
above the top of the door for tracks, springs, etc. to allow the door to
open properly. If the door is to be motor operated, 2-1/2” (64 mm) of
additional headroom is required.
bACkROOM REquIREMENT
MANuAL MOTOR
LIfT
DOOR hEIghT
TRACk
OPERATED
bACkROOM REquIREMENT: Backroom is defined as the distance
needed from the opening back into the garage to allow the door to
open fully.
6’0”, 7’0”
7’6”, 8’0”
12”, 15” Radius
12”, 15” Radius
98”
125”
110”
137”
6
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Installation
Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb and level with header. Side clearance, from
edge of door to wall, must be a minimum of 3-1/2” (89mm) on each side.
IMPORTANT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MUST BE USED WhEN INSTALLING CENTER BEARING BRACkETS, END BRACkETS, jAMB BRACkETS,
OPERATOR MOUNTING/SUPPORT BRACkETS AND DISCONNECT BRACkETS ON TREATED LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT 2000 COATED LAG
SCREWS ARE NOT NECESSARY WhEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.
NOTE: It is recommended that 5/16” lag screws be pilot drilled using a 3/16” drill bit, prior to fastening.
NOTE: Use this manual in conjunction with the windload specification sheet provided with your door.
quick install tab unlocked
quick install tab locked
Attaching quick Install flag
Angle to vertical Track
1
NOTE: If you have fully adjustable flagangles, skip
this step and complete Step 2.
Tools Needed:
None
Place the lower quick install tab of the flagangle in
the quick install feature of the vertical track. Give the
flagangle 1/4 turn to lock in place. Repeat for other
side.
Flagangle
Flagangle
NOTE: After completing this step, continue with Step
3.
Vertical
track
Vertical
track
Left hand track and flagangle
Right hand track and flagangle
Fully adjustable
flagangle
(2) 1/4”- 20 x 9/16”
Track bolts
Attaching fully Adjustable
flagangle to vertical Track
2
Tools Needed:
None
NOTE: If you have quick install flagangles, skip
this step and complete Step 3.
Attaching fully adjustable flagangle to
universal vertical track:
hand tighten the flagangle to the vertical track
using (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4”
- 20 flange hex nuts. Repeat for other side.
Universal
vertical
track
(2) 1/4”- 20 Flange
hex nuts
Secure the flange nuts after flagangle spacing is
complete (Step 16).
(2) 1/4”- 20 Flange
hex nuts
Fully adjustable
flagangle
Attaching fully adjustable flagangle to quick
install vertical track:
hand tighten the flagangle to the vertical track
using (1) stud plate and (2) 1/4” - 20 flange hex
nuts. Repeat for other side.
Secure the flange nuts after flagangle spacing is
complete (Step 16).
Stud plate
quick install
vertical track
7
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Tabs
horizontal angle
horizontal Angle
3
Position the horizontal angle as shown. Place tabs
of horizontal angle in the key slot of horizontal track.
Using a hammer, tap the horizontal angle towards
the curved end of the track until the hole in track and
angle are aligned. Set tracks aside.
Tools Needed:
hammer
hole
hole
key slots
NOTE: For larger doors, a full length horizontal angle
may be spot welded to the horizontal track. If the
horizontal angle is not welded, the horizontal angle
will be installed as shown.
horizontal track
horizontal
track
horizontal angle
horizontal
track
horizontal
angle
Tabs
horizontal
key slots track
(jb-uS) jAMb bRACkET SChEDuLE
Installing jb-uS jamb brackets
DOOR
HEIGHT
NO. OF
SECTIONS
NO. OF JAMB
BRACKETS
LOCATION OF CENTER LINE OF JAMB BRACKETS
MEASURED FROM BOTTOM OF TRACK
(ALL DIMENSIONS 2”)
4
(EACH JAMB)
NOTE: The following (jB-US) denotes a slotted jamb
bracket.
Tools Needed:
Tape Measure
WINDLOAD SPECIfICATION 1101, 1102, 1120, 1121, 1122, 1140, 1141, 1143
6’-0”
6’-6’’
7’-0’’
7’-6’’
8’-0’’
4
4
4
5
5
1
2
2
1
2
33 1/2” (JB-US)
Measure the length or the vertical track. Using the
jamb bracket schedule, determine the placement
of the jamb brackets for your door height and track
type.
34” (JB-US), 56” (JB-US)
29 1/2” (JB-US), 63 1/4” (JB-US)
28 1/2” (JB-US)
34” (JB-US), 58” (JB-US)
Loosely fasten the (jB-US) jamb bracket to the track
with a 1/4”-20 x 9/16” track bolt and nut.
WINDLOAD SPECIfICATION 1123
6’-0”
6’-6’’
7’-0’’
4
4
4
2
3
4
2” (JB-US), 23” (JB-US), 33 1/2” (JB-US)
2” (JB-US), 23 1/2” (JB-US), 34” (JB-US), 56” (JB-US)
2” (JB-US), 25 1/2” (JB-US), 34” (JB-US), 63 1/4”
(JB-US)
7’-6’’
8’-0’’
5
5
4
5
2” (JB-US), 24 1/2” (JB-US), 32 1/2” (JB-US), 49”
(JB-US)
Vertical
track
2” (JB-US), 23” (JB-US), 34” (JB-US), 58” (JB-US), 75
1/2” (JB-US)
(jB-US) jamb
bracket
WINDLOAD SPECIfICATION 1103, 1104, 1124, 1125, 1142, 1144
(1) 1/4” -
20 X 9/16”
Track bolt
6’-6’’
7’-0’’
7’-6’’
4
4
5
7
7
8
2” (JB-US), 10” (JB-US), 21 3/4” (JB-US), 29 3/4” (JB-
US), 39” (JB-US), 48” (JB-US), 57 1/4” (JB-US)
2” (JB-US), 10” (JB-US), 21 3/4” (JB-US), 29 3/4” (JB-
US), 42” (JB-US), 52 1/2” (JB-US), 63 1/4” (JB-US)
2” (JB-US), 10” (JB-US), 18 3/4” (JB-US), 26 3/4”
(JB-US), 36” (JB-US), 45” (JB-US), 54 1/4” (JB-US), 74
1/2” (JB-US)
(1) 1/4”- 20
Flange hex nut
8’-0’’
5
8
2” (JB-US), 10” (JB-US), 21 3/4” (JB-US), 29 3/4”
(JB-US), 39” (JB-US), 48” (JB-US), 57 1/2” (JB-US), 75
1/2” (JB-US)
(jb-uS) jAMb bRACkET INSTALLATION
8
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q.I. jAMb bRACkET SChEDuLE
Installing q.I. jamb brackets
WINDLOAD SPECIfICATION 1100, 1101, 1102, 1120, 1121, 1122, 1123, 1140, 1141, 1143
5
1ST SET
2ND SET
3RD SET
DOOR
hEIghT
NOTE: The following (q.I.) denotes a quick install
jamb bracket. No additional hardware is needed.
Tools Needed:
Tape Measure
jAMb bkT POSITION jAMb bkT POSITION jAMb bkT POSITION
6’0”
(4 SECTIONS)
qIjB - 9
qIjB - 9
qIjB - 9
qIjB - 9
qIjB - 9
Middle
Middle
Middle
Top
qIjB - 11
qIjB - 10
qIjB - 10
qIjB - 10
qIjB - 10
Middle
Bottom
Bottom
Middle
Middle
Not applicable
Not applicable
Not applicable
Measure the length or the vertical track. Using the
jamb bracket schedule, determine the placement
of the jamb brackets for your door height and track
type.
6’6”
(4 SECTIONS)
Align the twistlock tab on (q.I.) jamb bracket with the
quick install feature in the track and turn the jamb
bracket perpendicular to the track so the mounting
flange is toward the back leg of the track.
7’0”
(4 SECTIONS)
7’6”
(5 SECTIONS)
qIjB - 11
Middle
Middle
8’0”
(5 SECTIONS)
Top
qIjB - 11
Twist lock
Top hole
tabs
Middle hole
Bottom hole
q.I. jamb bracket
LEfT SIDE ShOWN
RIghT SIDE ShOWN
quICk INSTALL
fEATuRE
q.I. jAMb bRACkET
(q.I.) jAMb bRACkET INSTALLATION
u-bar Schedule
bottom bracket
Position of
u-bar on
section
6
Windload Option Codes: 1104 / 1123 /
1124 / 1125 /1142 / 1143 / 1144
Door height
Section
NOTE: For door section identification see page 4.
IMPORTANT: RIGhT AND LEFT hAND IS ALWAYS
DETERMINED FROM INSIDE ThE GARAGE LOOkING
OUT.
Tools Needed:
Power Drill
7/16” Socket Driver
1/4” Torx bit
6’- 0” to 8’- 0”
Bottom
Bottom
X
Bottom
section
End stile
1
Needle Nose Pliers
Warning
label
Refer to the u-bar schedule to determine if the
bottom section requires a u-bar. If the bottom section
requires a u-bar, position the u-bar over the bottom
brackets and center the u-bar side to side on the
bottom section.
2
3
#3 hole
4
5
6
U-bar
Bottom
bracket
NOTE: Refer to illustrations (A) or (b) to determine
which bottom bracket was supplied with your door.
Follow the corresponding step below:
(1) 1/4”- 14 x 5/8”
Self drilling tamper-
resistant screw
7
(2) 1/4”- 14 x 7/8”
Self drilling screws
bOTTOM bRACkET (A): Align the center hole of left
hand bottom bracket with hole #3 in the end stile
of the bottom section. Attach the left hand bottom
bracket with (1) 1/4”-14 x 5/8” self tamper-resistant
drilling screw. Position a u-bar (if applicable) over the
bottom brackets and center the u-bar side to side on
the bottom section. Secure the u-bar / bottom bracket
into the endstile using (2) 1/4”-14 x 7/8” self drilling
screws. Repeat for the right hand side. Now, finish
securing the u-bar to the section using (2) 1/4”-14 x
7/8” self drilling screws at each center stile location.
(A)
7
6
Left hand
bottom
bracket
Counterbalance
cable
5
4
3
2
1
bOTTOM bRACkET (b): Uncoil the counterbalance
cables and secure the cable loop to the clevis pin and
bottom bracket using a 5/16” flat washer and cotter
pin. Repeat for other bottom bracket.
END STILE hOLE
PATTERN (LEFT SIDE
IS ShOWN. RIGhT
SIDE IS OPPOSITE.)
Clevis
Pin
(b)
9
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bottom bracket Continued...
End
Stile
Warning
label
Bottom
bracket
Attach the bottom bracket to the bottom corners
of section and secure using (4) 1/4”-20 x 7/8” self
drilling screws and (1) 1/4”-20 x 5/8” tamper-
resistant self drilling screw as shown. Repeat for
other side. Position a u-bar (if applicable) over the
bottom brackets and center the u-bar side to side on
the bottom section. Secure the u-bar / bottom bracket
into the endstile using (2) 1/4”-14 x 7/8” self drilling
screws. Repeat for the right hand side. Now, finish
securing the u-bar to the section using (2) 1/4”- 14 x
7/8” self drilling screws at each center stile location.
(4) 1/4”- 14 x 7/8”
Self drilling screws
Cotter Pin
Washer
U-bar
(2) 1/4”- 14 x 7/8”
Self drilling screws
NOTE: All doors are provided with the tamper
resistant fasteners for the bottom brackets. however,
the professional installer is most likely to have the
proper tool to install this fastener. If the homeowner
does not have the proper tool to install the tamper
resistant fastener, use a regular 1/4” - 14 x 7/8” self
drilling screw in its place.
(1) 1/4”- 14 x 5/8”
Self drilling tamper-resistant
screw
(b)
Bottom
section
Stile
U-bar
Warning
label
for windload specification option codes 1124,
1125, 1142 and 1144: Extension brackets, long
stem rollers and spacer are required. Position the
extension bracket flush against the end stile and
slide it underneath the u-bar (if applicable). Align
the extension bracket with the bottom bracket by
inserting a long stem roller with spacer through the
bottom bracket and extension bracket hinge tubes.
Attach the extension bracket to the endstile with (2)
1/4” -14 x 7/8” self drilling screws as shown.
Repeat for other side.
(A) or (B)
bottom bracket
(2) 1/4”- 14 x 7/8”
Self drilling screws
hinge tubes of bottom bracket
Spacer
hinge tube
of extension
bracket
Long stem roller
WINDLOAD SPECIfICATION OPTION CODES 1124, 1125, 1142 AND 1144
Counterbalance
cable
Counterbalance
cable
Counterbalance Cables
7
Bottom
section
NOTE: For door section identification see page 4.
Tools Needed:
None
Milford
pin
IMPORTANT: RIGhT AND LEFT hAND IS ALWAYS
DETERMINED FROM INSIDE ThE GARAGE LOOkING
OUT.
Cable
loop
hinge
tube
Uncoil the counterbalance cables and place the cable
loop on the milford pin.
Spacer
Short stem
roller
Milford pin
NOTE: Depending on the bottom bracket that was
provided with your door, you may already have the
counterbalance cable installed. Refer to Step 6.
Counterbalance
cable
Insert a short stem roller with a spacer into bottom
bracket of the bottom section.
Repeat for other side.
Bottom
bracket
NOTE: Verify astragal (bottom seal) is aligned with
door section. If there is more than 1/2” excess
astragal on either side, trim astragal even with door
section.
Cable
loop
Milford pin
Long stem
roller
Bottom section
Astragal
10
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hinge Schedule
End hinges
Wide end Narrow end
hinges
Wide
center
hinges
Option codes
1100, 1120
quantity # of end
hinges per side
hinges
hinges
NOTE: Refer to the door section identification on
page 4 to determine your lock (second), intermediate
(third), intermediate II (fourth section on a five section
door), and top sections. Measure your sections to
make sure they are the correct height as indicated
on the chart.
Tools Needed:
Power Drill
1
1
None
Yes
None
None
7/16” Socket Driver
1101, 1102,1103, 1104, 1121,
1122, 1123, 1140, 1141, 1143
Yes
Yes
None
None
As
required
1124, 1125, 1142, 1144
2
Refer to the hinge schedule to determine the ap-
propriate hinges for your door.
fOR WINDLOAD OPTION CODES (A): 1100 OR 1120:
One narrow end hinge, narrow center hinge(s) and a
short stem roller are required, per side.
fOR WINDLOAD OPTION CODES (b): 1101, 1102,
1103, 1104, 1121, 1122, 1123, 1140, 1141, or 1143:
One wide end hinge, narrow center hinge(s) and a
short stem roller are required, per side.
Roller
placement
Roller
placement
Roller
placement
Roller
placement
1
3
2
4
#1 Wide hinge
#2 Wide hinge
#3 Wide hinge
#4 Wide hinge
fOR WINDLOAD OPTION CODES (C): 1124, 1125,
1142, or 1144: Two wide end hinges, wide center
hinge(s) and a long stem roller are required, per side.
Locate the bottom section, using #1 hinges for the
end stiles and depending on the width of your door,
enough #1 hinge(s) for each of the center stile(s)
location.
Place the hinges on the section so that the lower (#)
leaf of the hinge is over the pre-punched holes in
the #1 and #4 of the end stiles and the pre-punched
holes of the center stile(s) at the top of the section.
(See end stile hole pattern on page 9.) Secure the
hinges to the section using (2) 1/4” - 14 x 7/8” self
tapping screws for each, then insert the roller into the
appropriate end hinge tube.
Roller
placement
#4 Narrow hinge
Roller
placement
#1 Narrow hinge
Roller
placement
#3 Narrow hinge
Roller
placement
#2 Narrow hinge
1
4
2
3
Wide end hinge
Narrow end hinge
#1
Short stem
roller
Short stem
roller
NOTE: The #1 hinges serve as end hinges and center
hinges on the bottom section. The #1 hinges also
serve as center hinges at all center hinge locations.
1
1
#4
End stile
End stile
Use #2 end hinges and #1 center stile hinges for the
lock section (second section) of the door.
(2) 1/4”- 14 x 7/8”
Self drilling screws
(2) 1/4”- 14 x 7/8”
Self drilling screws
(A) NARROW END hINGE INSTALLATION
(b OR C) WIDE END hINGE INSTALLATION
Use #3 end hinges and #1 center stile hinges for the
intermediate section (third section) of the door.
Typical
center hinge
Wide end
hinge
Use #4 end hinges and #1 center stile hinges for the
intermediate section II (fourth section) of the door.
Previously installed
Wide end hinge
IMPORTANT: WhEN PLACING ROLLERS INTO END
hINGES NUMBER 2 AND hIGhER, ThE ROLLER GOES
INTO TUBE FURThEST AWAY FROM SECTION.
Long stem
roller
1
NOTE: #4 End hinges are used on fourth section of a
1
five section door.
Center
stile
Stile
(2) 1/4”- 14 X 7/8”
Self drilling screws
(2) 1/4”- 14 x 7/8”
Self drilling screws
(C)
TYPICAL CENTER hINGE INSTALLATION
11
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Top bracket
9
NOTE: Refer to illustrations (A) or (b) to determine
which top bracket was supplied with your door.
Follow the corresponding step below:
Tools Needed:
Power Drill
Top
7/16” Socket Driver
section
for Top bracket (A): Align upper-center hole of
the top bracket base with #6 hole in the end stile
(See End Stile hole Pattern on Pg 9). Ensure the top
bracket base is level and aligned with the edge of
the section. Secure the top bracket assembly to the
endstile using (4) 1/4” - 20 x 7/8” self drilling screws.
End
stile
Top bracket
base
Insert a short stem roller into the top bracket slide.
The top bracket slide will be adjusted and tightened
in Step 18. Repeat for the opposite side.
Center hole
(2) 1/4”-20
Flange hex
nuts
for Top bracket (b): Align upper-center hole of
the top bracket base with #6 hole in the end stile
(See End Stile hole Pattern on Pg 9). Ensure the
top bracket base is level and aligned with the edge
of the section. Secure the top bracket assembly to
the endstile using (4) 1/4” - 20 x 7/8” self drilling
screws. Loosen the 5/16” - 18 nut on the top bracket
assembly. Insert a short stem roller into the top
bracket slide. The top bracket slide will be adjusted
and tightened in Step 18. Repeat for the opposite
side.
Top bracket
slide
Short stem
roller
NOTE: For windload specification option codes 1124,
1125, 1142 and 1144, do not insert a short shaft
roller.
(4) 1/4”- 20 x 7/8”
Self drilling screws
(A)
for windload specification option codes 1124,
1125, 1142 and 1144 (C): Two top bracket
assemblies and a long stem roller are required.
Loosen the 5/16” - 18 nut on the top bracket
assembly and position it flush against the stile,
and centered on the stile. Insert a long stem roller
through both slides of the top bracket assembly’s
to align. Secure the top bracket assembly to stile
using (4) 1/4” - 20 x 7/8” self drilling screws. The top
bracket slide will be adjusted and tightened in Step
18. Repeat for other side.
Top
section
Top bracket
assembly
#6 hole
Center hole
(1) 5/16”- 18 x 5/8”
Carriage bolt and (1)
5/16”- 18 hex nut
Short stem
roller
End
stile
(4) 1/4”- 14 x 7/8”
Self drilling screws
(b)
Stile
Top bracket
assembly
(1) 5/16”- 18 x
5/8” Carriage bolt
and (1) 5/16”- 18
hex nut
(1) 5/16”- 18 x 5/8”
Carriage bolt and (1)
5/16”- 18 hex nut
Long stem roller
(1320/1340 only)
(4) 1/4”- 14 x 7/8”
Self drilling screws
(C)
12
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Top section
Bottom
section
u-bar
U-bar
NOTE: For door section identification see Page 4.
Tools Needed:
Power Drill
Refer to the u-bar schedule to determine the required
number of u-bar(s), and placement on each section.
7/16” Socket Driver
U-bar
NOTE: U-Bars are typically placed flush against the
upper or lower hinge leafs, except on the bottom of
the bottom section, and top of the top section.
Top bracket
assembly
(2) 1/4”- 14 x 7/8”
Self drilling screws
Place the sections face down on a couple of
sawhorses or flat clean/ smooth surface. Butt the
sections together in the proper stack sequence and
flip up the hinges. Position the u-bars according to
the u-bar schedule, and flush against the hinge leafs
(or just above the bottom brackets on the bottom
section, if applicable). Center the u-bars side to side
on the section, and secure using (2) 1/4” -14 x 7/8”
self drilling screws at each end stile and center stile
location. Repeat for all other sections except the top
of the top section.
(2) 1/4”- 14 x 7/8”
Self drilling screws
Bottom bracket
assembly
U-BAR PLACEMENT FOR TOP SECTION
U-bar
U-BAR PLACEMENT FOR BOTTOM SECTION
Attaching
center
stile
INSTALLATION ON ThE TOP SECTION: Position the
u-bar above the top bracket assembly. Center the u-
bar side to side on the section, and secure using (2)
1/4” - 14 x 7/8” self drilling screws at each end stile
and center stile location.
hinge
U-bar
U-bar
U-bar
(2) 1/4”- 14 x 7/8”
Self drilling screws
(2) 1/4”- 14 x 7/8” Self drilling screws
U-BAR PLACEMENT FOR LOCk AND INTERMEDIATE SECTIONS
u-bar Schedule
Specification Options Code
1100/1101
1102
1103
1104
1120/1121
1122
1123/1124 1125 1140 1141 1142 1143/1144
Bottom
Top
X
X
X
X
X
X
X
X
X
X
X
X
Bottom
Lock
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Bottom
Top
X
X
X
X
X
X
X
X
X
X
X
X
X
6’- 0” to
4
7’- 0”
Bottom
Top
X
Intermediate I
Top
Bottom
Top
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Bottom
Top
Bottom
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Bottom
Top
X
Lock
X
X
X
X
X
X
X
X
X
X
Bottom
Top
X
7’- 6” to
5
Intermediate I
Intermediate II
Top
8’- 0”
X
X
X
X
X
X
X
X
X
X
X
Bottom
Top
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Bottom
Top
X
X
X
13
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Step Plate
Bottom section
11
Locate the center most stile of the bottom section of
the door.
Tools Needed:
Pencil
8” Max mounting
height
On the inside of the door, center the step plate/lift
handle on the center most stile no higher than 8”
from the bottom of the door. Using the step plate/lift
handle holes as a guide, drill a 5/16” dia. hole along
each side of the stile through the face of the door. Be
extremely careful to keep drill straight.
Power Drill
5/16” Drill Bit
7/16” Wrench
Bottom section
(2) 1/4”-20
Flange hex nuts
Step plate assembly
Mount step plates / lift handles back to back,
straddling stile. Secure with (2) 1/4” x 2-3/4”
carriage bolts and 1/4”-20 flange hex nuts.
Step plate
INSIDE STEP PLATE INSTALLATION
Bottom section
8” Max mounting
height
Bottom section
Step plate assembly
Step plate
(2) 1/4 x 2-3/4” carriage bolts
OUTSIDE STEP PLATE INSTALLATION
Enlarge holes on
outside of section to
1/2” diameter.
Lock section
Lift handle
Lock section
Lift handle
Lift handle
12
NOTE: Doors with a keyed lock do not require this
Tools Needed:
Tape Measure
lift handle.
NOTE: For door section identification see page 4.
Pencil
4”
Power Drill
Locate the inside center most stile or the desired lift
handle location on the lock (2nd) section of the door.
Position the lower hole in the lift handle 4” from the
bottom of the second section.
9/32” Drill Bit
1/2” Drill Bit
7/16” Wrench
(2) Spacers
4”
Vertically align the lift handle, use the lift handle as a
template and mark the hole locations on the section.
Bottom
Section
(2) 1/4” x 2-1/2”
Carriage bolts
Drill (2) 9/32” dia. holes through section. Enlarge the
holes from outside the door to 1/2” dia.
LIFT hANDLE OUTSIDE
Lock
section
Assemble the outside and inside lift handle to the
section using (2) 1/4” x 2-1/2” carriage bolts and
nuts and (2) spacers.
9/32” Diameter
holes (do not
enlarge holes).
Bottom
section
NOTE: Do not drill through or enlarge holes on the
inside of the door.
WARNINg
TO AVOID POSSIBLE INjURY, LIFT hANDLES ThAT
ARE INSTALLED WIThIN 4 INChES (102 mm) OF A
SECTION INTERFACE ShALL PROMOTE VERTICAL
ORIENTATION OF ThE hAND.
Lift handle
(2) 1/4”-20
hex nuts
Bottom section
LIFT hANDLE INSIDE
14
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bottom Section
13
header
Center the bottom section in the door opening.
Level section using wooden shims under the bottom
astragal if necessary. hold the section in the opening
while attaching vertical tracks.
Tools Needed:
Level
Wood Shims
jamb
Weather
seal
Level
Bottom
section
Wooden
shims
Flagangle
Cable
vertical Track
Vertical
track
5/8”
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.
Tools Needed:
3/16” Drill Bit
Power Drill
7/16” Socket Driver
Tape Measure
Level
Roller
Bottom section
Position the left hand vertical track assembly over
the rollers of the bottom section. Make sure the
counterbalance cable is located between the rollers
and the door jamb. Drill 3/16” pilot holes for the lag
screws.
5/16 X 1-5/8”
Lag screws
Step Ladder
Vertical track
assembly
Loosely fasten jamb brackets and flagangle to the
jamb using 5/16” x 1-5/8” lag screws. Tighten lag
screw securing bottom jamb bracket to jamb, to
maintain 5/8” spacing. hang counterbalance cable
over flagangle.
Lag
screw
Locations
Lag
screw
Locations
jamb
Bracket
Repeat for the right hand side.
F.A.T. FLAGANGLE
q.I. FLAGANGLE
5/16” x 1-5/8”
Lag screw
jamb bracket
Bottom
section
15
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Stacking Sections
NOTE: For door section identification see page 4.
NOTE: Make sure hinges are flipped down, when
stacking another section on top.
Tools Needed:
Power Drill
Lock
section
7/16” Socket Driver
With assistance, lift second section and guide rollers
into the vertical tracks. keeping the ends of the
sections aligned, install remaining section(s), except
top section, in same manner.
Starting with the center most hinge, flip up the hinge
leaf, and hold it tight against section. Secure it to the
section using (2) 1/4”- 14 x 7/8” self drilling screws.
Repeat for all remaining center hinges.
for windload option codes (A): 1100
Flip up the left hand end hinge(s) leaf, and hold tight
against the section while securing it to the section
using (2) 1/4”- 14 x 7/8” self drilling screws. Repeat
for the right hand end hinge(s).
Section
hinge
leaf
for windload option codes (b): 1101, 1102, 1103,
1104, 1120, 1121, 1123, 1140, 1141, 1142 or 1143
Flip up the left hand end hinge(s) leaf, and hold tight
against the section while securing it to the section
using (4) 1/4”- 14 x 7/8” self drilling screws. Repeat
for the right hand end hinge(s).
(2) 1/4” - 14 x 7/8”
Self drilling screws
for windload option codes (C): 1124, 1125, 1142
or 1144
Flip up the left hand end hinge(s) leaf, and hold tight
against the section while securing it to the section
using (6) 1/4”- 14 x 7/8” self drilling screws. Repeat
for the right hand end hinge(s).
CENTER hINGE
Repeat for other sections except the top section.
hinge
leaf
hinge
leaf
NOTE: Install lock at this time (sold separately) see
side lock instructions in optional installations on
page 26.
Section
Section
(2) 1/4” - 14 x 7/8”
Self drilling screws
(4) 1/4” - 14 x 7/8”
Self drilling screws
(A)
(B)
hinge leafs
Section
(6) 1/4” - 14 x 7/8”
Self drilling screws
(C)
16
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Flagangle
Top Section
16
Door width
+3-3/8” to 3-1/2”
Place the top section in the opening and vertically
align with lower sections.
Tools Needed:
hammer
Nail
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.
Power Drill
7/16 Socket Driver
Tape Measure
Step Ladder
Flagangle
Now flip up hinge leaf against section, fastening
center hinges first, and end hinges last. (Refer to
Step 15).
Position flagangle between 1-11/16” (43 mm) to 1-
3/4” (44 mm) from the edge of the door. Tighten the
bottom lag screw. Flagangles must be parallel to the
door sections. Repeat for opposite side.
IMPORTANT: ThE DIMENSION BETWEEN ThE
FLAGANGLES MUST BE DOOR WIDTh PLUS 3-3/8”
(86MM) TO 3-1/2” (89 MM) FOR SMOOTh, SAFE
DOOR OPERATION.
for quick install track:
Complete the vertical track installation by securing
the center jamb bracket(s) and tightening the other
lag screws. Repeat for opposite side.
for fully adjustable track:
Complete the vertical track installation by securing
the center jamb bracket(s) and tightening the other
lag screws. Push the vertical track against the rollers
so that the rollers are touching the deepest part of
the curved side of the track (see illustration); tighten
all the track bolts and nuts. Repeat for opposite side.
Vertical track
Nail
Roller
Top section
Roller against
vertical track
1-11/16” To 1-3/4”
Flagangle
Top section
17
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Attaching flagangle
to horizontal Track
Flagangle
NOTE: Refer to illustrations (A) or (B) to determine
which horizontal track was supplied with your door.
Follow the corresponding step below:
q.I. horizontal track
Tools Needed:
9/16” Socket
7/16” Socket
Ratchet Wrench
9/16” Wrench
Level
hammer
Flat Tip
Screwdriver
Step Ladder
for quick install horizontal track (A): To install
horizontal track, place the curved end over the top
roller. Align the bottom of the horizontal track with the
vertical track. hand tighten the horizontal track to the
flagangle with (1) stud plate and (2) 1/4”- 20 flange
hex nuts.
(1) Stud plate
(2) 1/4”- 20
Flange hex
nuts
for universal horizontal track (b): To install
horizontal track, place the curved end over the top
roller. Align the bottom of the horizontal track with the
vertical track. hand tighten the horizontal track to the
flagangle with (2) 1/4”- 20 x 9/16” track bolts and (2)
1/4”- 20 flange hex nuts.
WARNINg
(A)
DO NOT RAISE DOOR UNTIL hORIzONTAL TRACkS
ARE SECURED AT REAR, AS OUTLINED IN STEP 26,
OR DOOR COULD FALL FROM OVERhEAD POSITION
CAUSING SEVERE OR FATAL INjURY.
Flagangle
Level the horizontal track assembly and bolt the
horizontal angle to the slot in the flagangle using (1)
3/8”- 16 x 3/4” truss head bolt and (1) 3/8”- 16 hex
nut. Repeat for other side. Remove the nail that was
temporarily holding the top section in place, installed
in Step 16.
Universal horizontal
track
IMPORTANT: FAILURE TO REMOVE NAIL BEFORE
ATTEMPTING TO RAISE DOOR COULD CAUSE
PERMANENT DAMAGE TO TOP SECTION.
(2) 1/4”- 20
Flange hex
nuts
(2) 1/4”- 20 X 9/16”
Track bolts
(B)
Flagangle
3/8”- 16 X 3/4”
Truss head bolt
horizontal angle
3/8”- 16
hex nut
18
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(1) 1/4” - 20 X 9/16” Track
bolt and (1) 1/4” - 20 hex nut
(1) 5/16” - 18
Nut
Top section
horizontal
track
Adjusting Top brackets
18
With horizontal tracks installed you can adjust the top
brackets. Vertically align the top section with the lower
sections. Once aligned, position the top roller in the
adjustable slide(s), out against the horizontal track.
fOR WINDLOAD OPTION CODES (A): 1100 OR 1120:
Maintaining the slide’s position, tighten the (1) 1/4”
- 20 flange hex nuts to secure the slide to the top
bracket. Repeat for other side.
Short shaft
roller
Tools Needed:
7/16” Wrench
1/2” Wrench
Step Ladder
(2) 1/4” - 20
Flange hex nuts
Top bracket
slide
Tape Measure
fOR WINDLOAD OPTION CODES (b): 1101, 1102,
1103, 1104, 1121, 1122, 1123, 1140, 1141 OR 1143:
Maintaining the slide’s position, tighten the (1) 5/16”-
18 nut to secure the slide to the top bracket base.
Now lock the slide in position using (1) 1/4” - 20 x
9/16” track bolt and (1) 1/4” - 20 hex nut through any
aligning hole. Repeat for other side.
Short shaft
roller
Top bracket
horizontal
track
slide
Correct
Top section
(A)
(b)
fOR WINDLOAD OPTION CODES (C): 1124, 1125,
1142 or 1144: Maintaining the slide’s position, tighten
the (2) 5/16” - 18 nuts to secure the slides to the top
brackets. Now lock the top slides in position using (2)
1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 hex
nuts through any two aligning holes. Repeat for other
side.
(2) 1/4” - 20 X 9/16”
Track bolts and (2)
1/4” - 20 hex nuts
Top bracket
assembly’s
NOTE: If you have windload option codes 1121, 1122,
1123, 1124, 1125, 1141 and 1142, pushnuts are
required to be installed.
IMPORTANT: ACCURATELY POSITIONING ThE
PUShNUT ONTO ThE ROLLER STEM IS CRITICAL.
ONCE ThE PUShNUT IS PUShED ONTO ThE ROLLER
STEM, ThE TABS MAkING CONTACT WITh ThE STEEL
SURFACE, WILL MAkE IT DIFFICULT TO REPOSITION
ThE PUShNUT.
NOTE: When positioning the pushnut onto roller stem,
ensure the tabs on the pushnut are pointing away
from roller stem.
Starting with the top bracket assembly, slide (1)
pushnut over the roller stem and push the pushnut
towards the outside edge of top bracket assembly
leaving 1/4” spacing between the outside edge of top
bracket assembly and pushnut.
Top bracket
slide
horizontal
track
Top section
Top bracket
slide
Long shaft
roller
(2) 5/16” - 18
Nuts
(C)
Incorrect
End hinge
1/4” spacing
1/4” spacing
Top bracket
assembly
Pushnut
Pushnut
Repeat same process for the end hinges on the left
hand side of door, then repeat same process for other
side of door.
Roller stem
Roller stem
Left hand end
bearing bracket
Torsion End bearing brackets
19
End bearing brackets are right and left hand.
Break the end bearing brackets apart.
Tools Needed:
Step Ladder
Upper slots
Used on 15”
Radius track.
Lower slots on
12” radius track.
Starting on the left hand side and using the upper
slots in the end bearing bracket, position above
the flagangle and secure the end bearing bracket
to the horizontal angle using (2) 3/8”-16 x 3/4”
truss head bolts and (2) 3/8”-16 nuts.
IMPORTANT: END BEARING BRACkETS MUST BE
ATTAChED ThROUGh ThE LOWER SLOTS ON 12”
RADIUS TRACk. 15” RADIUS TRACk MUST USE
ThE UPPER SLOTS ON ThE BRACkET.
Once the bracket is secured to the horizontal
angle, secure the top of the end bearing bracket
to the jamb using (1) 5/16” x 1-5/8” lag screw.
Repeat for right hand side.
Break the
end bearing
brackets
apart
Power Drill
horizontal
angle
Ratchet Wrench
7/16” Socket Driver
9/16” Socket Driver
9/16” Wrench
Left hand end
bearing bracket
(1) 5/16” X 1-5/8”
Lag screw
(2) 3/8”-16 X 3/4”
Truss head bolts
NOTE: Right and left hand is always determined
from inside the building looking out.
horizontal
angle
(2) 3/8”-16 Nuts
19
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Center bearing
bracket
Mounting
surface
Center bearing bracket
Equal
distance
20
Measure to locate the center of the door and mark
a vertical pencil line on the mounting surface above
the door, to indicate the center line of the door. Then,
measure from the center of the bearing, in one of
the end bearing brackets, DOWN to the top of the
door. Using that dimension, measure UP from the top
of the door and mark a horizontal pencil line on the
mounting surface, intersecting the vertical pencil line.
Now align the edge of the center bearing bracket
along the vertical pencil line on the mounting surface.
Center the bearing bracket on the horizontal line.
Tools Needed:
Power Drill
horizontal
line
Center of end
bearing bracket
7/16” Socket Driver
Level
Tape Measure
Pencil
Vertical
line
1/4” Torx Bit
This will ensure the torsion tube is level between the
center and end bearing brackets. Attach the center
bearing bracket, in this location, to the mounting
surface, using (2) 5/16” x 1-5/8” lag screws and (1)
5/16” x 2” tamper-resistant lag screw.
Mounting
surface
Center bearing bracket
(1) 5/16” x 1-5/8”
Lag screw
IMPORTANT: USE ThE 5/16” X 1 5/8” TAMPER-
RESISTANT LAG SCREW ONLY IF MOUNTING SURFACE
MOUNTED OVER MASONRY. TAMPER-RESISTANT LAG
SCREW MUST BE ATTAChED ThROUGh ThE BOTTOM
hOLE OF ThE CENTER BEARING BRACkET.
horizontal line
(1) 5/16” x 1-5/8”
Lag screw
(1) 5/16” x 2”
Tamper-resistant
lag screw or (1)
5/16” x 1-5/8” lag
screw
Vertical line
Torsion Spring Assembly
21
IMPORTANT: RIGhT AND LEFT hAND IS ALWAYS
DETERMINED FROM INSIDE ThE BUILDING LOOkING
OUT.
Tools Needed:
none
Right hand
cable drum
black
NOTE: Identify the springs provided as either right
hand wound (red winding cone), which goes on the
LEFT hAND SIDE or left hand wound (black winding
cone), which goes on the RIGhT hAND SIDE.
Facing the inside of the door, lay the torsion tube on
the floor. Lay the spring with the black color coded
winding cone and the black color coded cable drum,
at the right hand end of the tube.
Left hand
cable
drum red
Lay the spring with the red color coded winding cone
and the red color coded cable drum, at the left hand
end of the tube.
Torsion tube
NOTE: The set screws used on all torsion
counterbalance winding cones and cable drums, are
now colored red. DO NOT identify right and left hand
by the set screw color.
Nylon Center
bracket
bushing
20
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Nylon center
bracket bushing
Torsion Spring Assembly
Continued...
Right hand
cable drum
black
Right hand wound
Red winding cone
Left hand side
Slide the nylon center bushing onto the torsion tube
followed by the springs and cable drums. The nylon
center bushing, springs and cable drums must be
positioned, as shown.
Left hand cable
drum red
Torsion
tube
Left hand wound
Black winding cone
right hand side
With assistance, pick up the torsion assembly and
slide one end of the tube through one end bearing
bracket. Lay the torsion tube into the center bearing
bracket and slide the other end of the tube into the
opposite end bearing bracket. Position the torsion
tube so that equal amounts of the tube extend from
each end bearing bracket.
Equal
spacing
Center
bracket
Torsion
assembly
End bearing
bracket
Torsion
assembly
Torsion spring
Center bearing
bracket
Stationary
Nylon Center bushing
spring cone
22
9/16” Socket
Ratchet Wrench
9/16” Wrench
Slide the nylon center bushing into the stationary
spring cone at the end of the spring and align the
stationary spring cone(s) with the holes in the center
bearing bracket. Secure the spring(s) to the center
bearing bracket with (2) 3/8”-16 x 1-1/2” hex head
bolts and 3/8”-16 nuts.
Tools Needed:
Step Ladder
Stationary
spring cone
Spring
warning
tag
IMPORTANT: SPRINGS UNDER TENSION CAN BE
DANGEROUS.
Nylon center
bushing
IMPORTANT: ThE SPRING WARNING TAG(S)
SUPPLIED MUST BE SECURELY ATTAChED TO ThE
STATIONARY SPRING CONE IN PLAIN VIEW. ShOULD A
REPLACEMENT SPRING WARNING TAG BE REqUIRED,
CONTACT WAYNE-DALTON FOR FREE
Torsion
spring
Spring warning
tag
REPLACEMENTS.
(1) 3/8”-16 Nut
Center bearing bracket
(1) 3/8”-16 x 1-1/2”
hex head bolt
Torsion
spring
Torsion
spring
(1) 3/8”-16
Nut
(1) 3/8”-16 x 1-1/2”
hex head bolt
21
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Left cable drum
Counterbalance Cables
Cable
23
Thread the counterbalance cables around the back
side of the left cable drum and verify that there is no
cable obstructions. hook the cables into the drums.
Slide the left hand cable drum against the left hand
end bearing bracket and tighten the set screws in
the drum to 14-15 ft. lbs. of torque (Once set screws
contact the tube, tighten screws one full turn). Rotate
the left hand drum and torsion tube until cable is
taut. Attach vice grips to torsion tube and brace vice
grips against jamb to keep cable taut. Slide the right
hand cable drum against the right hand end bearing
bracket and rotate drum until cable is taunt. Tighten
set screws in right hand cable drum.
Tools Needed:
Vice Grips
3/8” Wrench
Cable
hooked in
cable drum
Vice
grips
Left end
bearing
bracket
jamb
IMPORTANT: ChECk EACh CABLE, MAkING SURE
BOTh ARE SEATED PROPERLY ON ThE CABLE
DRUMS AND hAVE EqUAL CABLE TENSION.
Left cable
drum
Torsion
tube
Set
Cable in
position
screws
Securing Door
for Spring Winding
24
Tools Needed:
Vice Clamps
Place vice clamps onto both vertical tracks just
above the third roller. This is to prevent the
garage door from raising while winding
counterbalance springs.
WARNINg
FAILURE TO PLACE VICE CLAMPS ONTO
VERTICAL TRACk CAN ALLOW DOOR TO RAISE
AND CAUSE SEVERE OR FATAL INjURY.
Place vice clamps
above 3rd Roller
Track
Vice clamps
attached to
track
22
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Winding Torsion Spring(s)
25
Position a ladder slightly to the side of spring so that
the winding cone is easily accessible, yet your body
is not in direct line with the winding bars.
Tools Needed:
Step Ladder
Approved Winding Bars
Check the label attached to the spring warning tag
for the required number of complete turns to balance
your door.
6’0” Door height = Approx. 6-7/8 Turns
6’6” Door height = Approx. 7-3/8 Turns
7’0” Door height = Approx. 7-7/8 Turns
7’6” Door height = Approx. 8-1/4 Turns
8’0” Door height = Approx. 8-3/4 Turns
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.
Spring
Winding
cone
Alternately inserting the winding bars into the holes
of the spring’s winding cone, rotate the winding cone
upward toward ceiling, 1/4 turn at a time, until the
required number of complete turns for your door
height is achieved. As the last 1/4 turn is achieved,
securely hold winding bar while tightening both set
screws in winding cone to 14-15 ft. lbs. of torque
(Once set screws contact the tube, tighten screws
one full turn).
Torsion
tube
Approved
Winding bars
Carefully remove winding bar from winding cone.
Repeat for the opposite spring. While holding the
door down, to prevent it from rising unexpectedly, in
the event the spring(s) were overwound, carefully
remove the vice grips from the torsion tube and the
vertical tracks.
Adjustments to the required from the number of
turns stated may be necessary. If door raises off floor
under spring tension alone, Reduce spring tension
until door rests on the floor. If the door is hard to
raise or drifts down on its own, add spring tension.
An unbalanced door such as this can cause garage
door opener operation problems.
Set
screws
Spring
Winding
cone
Approved
Winding bars
Torsion
tube
23
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Door in the up position
Rear Support
26
Raise the door until the top section and half of the
next section are in a horizontal position. Do not raise
door any further since rear of horizontal track is not
yet supported.
Tools Needed:
Ratchet Wrench
1/2” Socket
1/2” Wrench
(2) Vice Clamps
Step ladder
WARNINg
RAISING DOOR FURThER hER CAN RESULT IN DOOR
FALLING AND CAUSE SEVERE OR FATAL INjURY.
Clamp a pair of vice clamps on the vertical tracks
just above the second roller on one side, just below
the second roller on the other side. This will prevent
the door from raising or lowering while installing the
rear support. Using perforated angle, 5/16” x 1-5/8”
hex head lag screws and 5/16” bolts with nuts (may
not be supplied), fabricate rear support for horizontal
tracks. Attach horizontal tracks to the rear supports
with 5/16”- 18 x 1-1/4” hex bolts and nuts (may not
be supplied). horizontal tracks must be level and
parallel to door within 3/4” maximum of door edge.
Vice
clamps
WARNINg
Vertical
track
kEEP hORIzONTAL TRACk PARALLEL AND WIThIN
3/4” 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 hORIzONTAL TRACk
hANGER ThAT CANTILEVERS 4” OR MORE BEYOND A
SOUND FRAMING MEMBER.
NOTE: If rear supports are to be installed over
drywall, use 5/16” x 2” hex head lag screws, and
make sure lag screws engaged solid structural
lumber.
3/4”
3/4”
horizontal tracks
Door edges
NOTE: Angles must be attached to sound framing
members and nails should not be used.
Now, permanently attach the weather seal to both
door jambs and header. (Temporarily attached in
PREPARING ThE OPENING on page 6). Avoid pushing
weather seal stop too tightly against face of door.
Place the windload label on the intermediate section,
as shown.
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
Perforated angle
Weather
seal
OR FATAL INjURY.
Now, lift door and check its balance. Adjustments
to the required number of turns stated may be
necessary. If door raises off floor under spring tension
alone, reduce spring tension until door rests on the
floor. If the door is hard to raise or drifts down on its
own, add spring tension. A poorly balanced door can
cause garage door opener operation problems.
jamb
(3) 5/16”-18 x 1-1/4”
hex bolts and (3) 5/16”-
18 nuts
(3) 5/16”-18
Nuts
PERMANENTLY ATTAChED WEAThER
SEAL
24
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Intermediate
section
Rear Support Continued...
To adjust spring tension, fully close door. Apply vice
grips to track above third roller. Insert a winding bar
into the winding cone. On single spring doors, cable
tension must be maintained by placing vice grips
on torsion tube before loosening set screws in the
winding cone. Push upward on the winding bar while
carefully loosening the set screws in the winding
cone.
Windload
label
Sound framing
members
WARNINg
Perforated angle
BE PREPARED TO SUPPORT ThE FULL FORCE OF
ThE TORSION SPRING ONCE ThE SET SCREWS ARE
LOOSE.
Perforated angle - bolted using (2)
5/16” x 1-5/8” hex head lag screws
to ceiling member and parallel to
width of door. Space lag screws no
further than 24” apart.
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.
Bolt must extend into
the track to serve as a
roller stop
horizontal
track
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:
Sound framing members
Perforated angle
1.) Check the door for level.
2.) Check the torsion tube for level.
3.) Check the track spacing.
Perforated angle -bolted using
(2) 5/16” x 1-5/8” hex head
lag screws to ceiling members
and parallel to width of door.
Attach vertical perforated angle
between the (2) 5/16” x 1-5/8”
hex head lag screws, securing
perforated angle to ceiling
members.
4.) Check the counterbalance cables for equal
tension.
5.) Check the track for potential obstruction of the
rollers.
Bolt must extend into the track
to serve as a roller stop
horizontal
track
6.) Clamp locking pliers onto track and rewind
springs.
IMPORTANT: IF DOOR STILL DOES NOT OPERATE
PROPERLY, ThEN CONTACT A TRAINED DOOR SYSTEM
TEChNICIAN.
25
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Side Lock
D
Install the side lock on the second section of the door.
Square the lock assembly with the door section and
align with the square hole in the vertical track. The
side lock should be spaced approximately 1/8” in
from the section edge. Secure the lock to the section
with (4) 1/4”- 20 x 11/16” self drilling screws.
Tools Needed:
Power Drill
7/16” Socket Driver
Tape Measure
IMPORTANT: SIDE LOCkS MUST BE REMOVED OR
MADE INOPERATIVE IN ThE UNLOCkED POSITION IF
AN OPERATOR IS INSTALLED ON ThE DOOR.
NOTE: After completing this step, continue with Step
16 on page 17.
(4) 1/4”- 20 X 11/16”
self drilling screws
1/8”
No. 6 screw eye
Pull Rope
D
Tools Needed:
Power Drill
WARNINg
DO NOT INSTALL PULL ROPES ON DOORS WITh
ELECTRIC OPERATORS. ChILDREN MAY BECOME
ENTANGLED IN ThE ROPE CAUSING SEVERE OR FATAL
INjURY.
Drill Bit
Pull rope
Pilot drill the location for the No. 6 screw eye.
Screw the No. 6 screw eye into the wood jamb
approximately 48” to 50” (1220 to 1270 mm) from
the floor. Tie the pull rope to the screw eye and to the
bottom bracket as shown.
Bottom
bracket
Pull rope
26
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Trolley Operator
D
Tools Needed:
Tape Measure
WARNINg
OPERATOR MUST BE TESTED AT TIME OF
INSTALLATION AND MONThLY ThEREAFTER AS
DESCRIBED IN YOUR OPERATOR’S INSTALLATION
INSTRUCTIONS AND OWNER’S MANUAL, TO ENSURE
ThAT DOOR SAFETY FEATURES FUNCTION. FAILURE
TO TEST OR MAkE ANY NECESSARY ADjUSTMENTS
OR REPAIRS, CAN RESULT IN SEVERE OR FATAL
INjURY
Operator rail
Operator
bracket
1. Attach operator rail to suitable mounting
surface, 2 x 6 lumber minimum.
Cotter
pin
Clevis pin
2. Install operator rail 1” to 1-1/2” (25 - 38 mm)
above high arc of top section of the door.
Door arm to
trolley arm
3. Attach operator to ceiling using perforated
angle.
Trolley arm attachment
4. Mount operator to ceiling so that 1” to 1-1/2”
(25 - 38 mm) clearance is maintained between
trolley rail and top section when door is fully
open (trolley rail will slope down towards rear).
Perforated angle
Operator rail
5. Attach door arm to operator bracket with cotter
and clevis pin.
IMPORTANT: ANGLES MUST BE SECURELY ATTAChED
TO SOUND FRAMING MEMBER(S).
Operator
Framing members
Perforated angle
27
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Cleaning
CLEANINg yOuR gARAgE DOOR
IMPORTANT: DO NOT USE A PRESSURE WAShER ON YOUR GARAGE DOOR!
While factory-applied finishes on garage doors are durable, it is desirable to clean them on a routine basis. Some discoloration of the finish may occur when a door has
been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of direct exposure to sunlight.
Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, a periodic washing of the garage door
is recommended.
The following cleaning solution is recommended:
A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into five gallons of warm water will aid in the removal of most dirt.
NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.
NOTE: Be sure to clean behind weather stripping on both sides and top of door.
CAuTION: NEVER MIX CLEANSERS OR DETERGENTS WITh BLEACh.
gLASS CLEANINg INSTRuCTIONS
Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.
ACRyLIC CLEANINg INSTRuCTIONS
Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on particles. A soft, grit-free cloth,
sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic glazing. Dry glazing with a clean damp chamois.
NOTE: DO NOT USE any window cleaning fluids, scouring compounds, gritty cloths or solvent-based cleaners of any kind.
28
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Painting
SuRfACE PREPARATION fOR PAINTINg
Wax on the surface must be removed or paint peeling/flaking will result. To remove this wax, it will be necessary to lightly scuff the surface with a fine steel wool pad,
saturated with soapy water. A final wipe and rinse should be done with clean water only, to remove any loose particles and any soapy film residue.
Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or No. 400 sand paper to create a smoother surface.
Care must be taken to not expose the substrate under the paint. Once the substrate is exposed, the likelihood for rusting is greatly increased.
If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed area lightly and paint with a high quality metal primer, specifically intended for
galvanized surfaces, to protect the area from corrosion. Allow for drying time on primer can label before applying topcoat.
The surface of the factory-applied finish, that is being painted, must not be too smooth, or the paint will not adhere to it. It is advisable to test in an inconspicuous area, to
evaluate adhesion. If poor adhesion is observed, surface preparation for painting the factory-applied finish must be repeated until desired results are achieved. Again, care
must be taken to not expose the substrate under the paint.
Painting
After surface has been properly prepared, it must be allowed to dry thoroughly, and then coated immediately with premium quality latex house paint. Follow paint label
directions explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate is exposed and not properly primed, painting with latex paint may
cause accelerated rusting of the steel in the exposed area.
NOTES:
1. Repainting of finish painted steel doors cannot be warranted, as this condition is totally beyond the door manufacturer’s control.
2. Consult a professional coatings contractor if in doubt about any of the above directions.
3. Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers. Pay particular attention to acceptable weather
and temperature conditions in which to paint.
29
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Limited Warranty
MODEL 8000, 8100 and 8200
Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton (“Manufacturer”) warrants the sections of the door, which is described at
the top of this page, TEN (10) yEARS against:
(i) The door becoming inoperable due to rust-through of the steel skin of the door section’s, due to cracking, splitting, or other deterioration of the
steel skin.
(ii)
Peeling of the original paint on the door as a result of a defect in the original paint or in the application of the original paint coating, in cases
where the door sections and the original paint: (a) have not been subjected to adverse atmospheric conditions or contaminates (such
as salt water or other marine environment, or to toxic or abrasive substances, including those in the air); (b) have been maintained in
compliance with Manufacturer’s recommendations; and (c) have not been subject to physical abrasion, impacted by a hard object, or punctured
(including without limitation “paint rub” occurring in metal to metal contact and movement).
The Manufacturer warrants the garage door hardware (except springs) and the tracks of the above-described door, TEN (10) yEARS, against defects in material
and workmanship, subject to all the terms and conditions below.
The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Limited Warranty against defects in material and
workmanship for a period of ONE (1) yEAR from the date of installation.
This Limited Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as his/her
primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or to installations on rental
property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the premises is sold), nor does it extend
benefits to any other person. As a result this Limited Warranty does NOT apply to any person who purchases the product from someone other than an authorized Wayne-
Dalton dealer or distributor.
The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its components,
abuse, damage from corrosive fumes or substances, salt spray or saltwater air, fire, Acts of God, failure to properly maintain the door, or attempt to use the door, its
components or related products for other than its intended purpose and its customary usage. This Limited Warranty does not cover ordinary wear. This Limited Warranty will
be voided if the original finish is painted over, unless Manufacturer’s preparation and painting instructions are followed explicitly. This Limited Warranty will be voided if any
holes are drilled into the door, other than those specified by the Manufacturer.
ThIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY ThE MAGNUSON-MOSS ACT. NO WARRANTIES, EXPRESS OR IMPLIED (INCLUDING BUT NOT
LIMITED TO ThE WARRANTY OF MERChANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) WILL EXTEND BEYOND ThE TIME PERIOD SET FORTh IN uNDERSCORED bOLD
fACE TyPE IN ThIS LIMITED WARRANTY, ABOVE.
•
Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply
to you.
Any claim under this Limited Warranty must be made in writing, within the applicable warranty period, to the dealer from which the product was purchased.
Unless the dealer is no longer in business, a written claim to the Manufacturer will be the same as if no claim had been made at all.
At the Manufacturer’s option, pursuant to the dealer having notified the Manufacturer of a warranty claim, a service representative may inspect the product on
site, or Buyer may be required to return the product to the Manufacturer at Buyer’s expense. Buyer agrees to cooperate with any representative of the Manufacturer and to
give such representative full access to the product with the claimed defect and full access to the location of its installation.
If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty, the Manufacturer will cause the defective product to be repaired
or replaced. The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer, subject to applicable law. ThE REMEDY WILL
COVER ONLY MATERIAL. ThIS LIMITED WARRANTY DOES NOT COVER OThER ChARGES, SUCh AS FIELD SERVICE LABOR FOR REMOVAL, INSTALLATION, PAINTING, ShIPPING,
ETC.
Any repairs or replacements arranged by Manufacturer will be covered by (and subject to) the terms, conditions, limitations and exceptions of this Limited
Warranty; provided, however, that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed, and this Limited
Warranty will expire at the same time as if there had been no defect. If a claim under this Limited Warranty is resolved in a manner other than described in the immediately
preceding paragraph, then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product.
ThE REMEDIES FOR ThE BUYER DESCRIBED IN ThIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy. The liability of the
Manufacturer, whether in contract or tort, under warranty, product liability, or otherwise, will not go beyond the Manufacturer’s obligation to repair or replace, at its option,
as described above. ThE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEqUENTIAL DAMAGES, including (but not
limited to) damage or loss of other property or equipment, personal injury, loss of profits or revenues, business or service interruptions, cost of capital , cost of purchase or
replacement of other goods, or claims of third parties for any of the foregoing.
•
Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to
you.
No employee, distributor, dealer, representative, or other person has the authority to modify any term or condition contained in this Limited Warranty or to grant
any other warranty on behalf of or binding on the Manufacturer, and anyone’s attempt to do so will be null and void.
Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer.
The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio, USA, to the extent
permitted by law.
•
This Limited Warranty gives you specific legal rights and you may also have other rights, which may vary from State to State.
Thank you for your purchase
Covered by one or more of the following Patents; 5,408,724; 5,409,051; 5,419,010; 5,495,640; 5,522,446; 5,562,141; 5,566,740; 5,568,672; 5,718,533; 6,019,269; 6,089,304; 6,644,378;
6,374,567; 6,561,256; 6,527,037; 6,640,872; 6,672,362; 6,725,898; 6,843,300; 6,915,573; 6,951,237; 7,014,386; 7,036,548; 7,059,380; 7,121,317; 7,128,123; 7,134,471; 7,134,472; 7,219,392;
7,254,868. Canadian: 2,384,936; 2,477,445; 2,495,175; 2,507,590; 2,530,701; 2,530,74; 2, 2,532,824. Other uS and foreign Patents pending
Please Do Not Return This Product To The Store
Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local yellow pages business listings or go
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