8000, 8100, 8200 Extension Spring Installation Instructions and Owner’s Manual Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.wayne-dalton.com Copyright 2009 Wayne-Dalton Corp. IMPORTANT NOTICE! Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work. Instead, have a qualified door agency do the installation or repairs. Part No.
Table of Contents Important Safety Instructions............................................. 2 Package Contents...........................................................3-4 Door Section Identification................................................. 4 Tools Required................................................................... 5 Pre-Installation.............................................................5-10 Removing The Old Door..................................5-9 Preparing The Opening.............
NOTE: Depending on the door model, some parts listed will not be supplied if not necessary. rear supports may or may not be included with your door.
Package Contents Continued...
power drill Phillips Head Screwdriver pencil 7/16”, 1/2” & 9/16” Socket ratchet Wrench 9/32”, 1/2”, 3/16” & 1/8” drill bits level sawhorse Flat Tip Screwdriver vice grips 3/8”, 7/16” socket driver Safety Glasses Tape Measure 1/4” torx bit 1/4”, 3/8”, 7/16”, 1/2” & 9/16” Wrenches PRE-INSTALLATION Tools Required gloves hammer vice clamps Approved Winding Bars Step Ladder Removing An Old Door WARNING If your counterbalance system is other than those mentioned, do not attempt to work on i
P1 Tools Needed: Recommended tools from page 5 Torsion Spring Removal For Standard Lift WARNING TORSION SPRING ASSEMBLY Failure to use approved winding bars can cause spring energy to be released suddenly, resulting in severe or fatal injury. WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.
Tools Needed: Recommended tools from page 5 loosen lock nut counter gear/ cover A TorqueMaster® spring system can be identified by the end brackets. For single spring applications, the right hand end bracket will always have a drive gear, counter gear, counter cover, and a winding bolt head. The left hand end bracket will have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged.
TorqueMaster® Spring Removal continued... Tools Needed: Recommended tools from page 5 If the counterbalance cable is still taut and the TorqueMaster® spring tube is difficult to rotate, that is an indication that spring tension still exists on the left hand spring. Repeat Steps 1 and 2 for releasing spring tension on the left hand side. Step 4: Using a flat tip screwdriver, pry the counter gear and counter cover from the right hand end bracket (Fig. 4 on previous page).
Tools Needed: Recommended tools from page 5 Extension Spring Removal Step 1: Raise the door to the fully open position and place vice clamps to the back legs of both vertical tracks, below the bottom rollers to prevent the door from falling. By opening the door you release most of the spring tension. Carefully unfasten the S-hook from the horizontal angle. Remove cable, sheave and extension spring. Repeat for the other side. If safety cables are running through the extension springs, remove them also.
P5 Tools Needed: Recommended tools from page 5 Preparing the Opening WARNING suitable mounting surface 2” x 6” lumber minimum header board 2” x 6” lumber preferred Failure to securely attach a suitable mounting pad to structurally sound framing could cause springs to violently pull mounting pad from wall, resulting in severe or fatal injury. door height level header plumb jambs If you just removed your existing door or you are installing a new door, complete all steps in PREPARING THE OPENING.
IMPORTANT: Read instructions titled “p4” “Removing the old door” on page 9 and “p5” “PREPARING THE OPENING” on page 10 before attempting door installation. IMPORTANT: Stainless steel or PT 2000 coated lag screws MUST be used when installing center bearing brackets, end brackets, jamb brackets, operator mounting/support brackets and disconnect brackets on treated lumber (preservative-treated). Stainless steel lag screws are NOT necessary when installing products on untreated lumber.
2 Tools Needed: None Attaching Fully Adjustable Flagangle to Vertical Track Fully Adjustable flagangle NOTE: If you have quick install flagangle, skip this step and complete Step 3. 1/4”- 20 x 9/16” large head ribbed Track Bolts NOTE: If you have riveted track, skip this step. Hand tighten the flagangle to the vertical track using (2) 1/4”- 20 x 9/16” large head ribbed track bolts and (2) 1/4”- 20 flange hex nuts. Secure the flange nuts after flagangle spacing is complete (Step 15).
4 Tools Needed: None Installing Fully Adjustable Jamb Brackets NOTE: If you have quick install jamb brackets, skip this step and complete Step 5. NOTE: If you have riveted track, skip this step. 3rd Set ST-0 ST-1 The bottom jamb bracket is always the shortest bracket included with your door. If three jamb brackets are included with you door, the bottom center bracket is the middle bracket in height. The top jamb bracket is the tallest bracket included.
5 Tools Needed: None Installing Q.I. Jamb Brackets NOTE: If fully adjustable jamb brackets were installed in step 4, skip this step and continue with Step 6. If not, complete this step. NOTE: If you have riveted 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 type.
Tools Needed: Power Drill 7/16” Socket Driver 3 Align center hole of bottom bracket with hole #3 hole in end stile of bottom section. Fasten with (2) 1/4”- 20 x 11/16” self drilling screws and (1) 1/4”- 20 x 5/8” tamper-resistant self drilling screw as shown. 5 Bottom Bracket 4 6 7 (2) 1/4”- 20 x 11/16” self drilling screws NOTE: Only doors provided to professional installers, who have required tools will be supplied with a tamper-resistant fastener.
8 Tools Needed: Power Drill 7/16” Socket Driver Hinges 3 NOTE: For door section identification see page 4. 5 1 2 4 6 Located the bottom section, (2) #1 hinges for the end stiles and enough #1 hinge(s) for each of the center stile(s). 7 roller placement Place the hinge on the section so that the lower (numbered) leaf of the hinge is over the pre-punched holes in the end stiles and center stile(s) at the top of the section.
Tools Needed: Power Drill 7/16” Socket Driver Top Bracket Align upper-center hole of top bracket with #6 hole in the end stile (See End Stile Hole Pattern on page 15). Ensure top bracket is level and aligned with edge of section. Secure with (2) 1/4”- 20 x 11/16” self drilling screws, one in each top corner of the top bracket. Ensure top bracket is level and aligned with edge of section. Secure with (2) 1/4”- 20 x 11/16” self drilling screws, one in each bottom corner of the top bracket.
10 Tools Needed: Step Plate bottom section Locate the center most stile of the bottom section of the door. On the inside of the door, center the step plate/lift handle on the center most stile no higher than 6” 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. (Drill through insulation and door’s face on an insulated door.) Be extremely careful to keep drill straight.
U-Bar Tools Needed: Power Drill NOTE: U-Bars are required on all doors 14’ wide and over. 7/16” Socket Driver NOTE: All U-Bars are placed at the top of the section. bottom section Hinge Hinge U-Bar U-Bar NOTE: The intermediate I section is the third section from the bottom on a 5 section door. The intermediate II section is the fourth section from the bottom on a 5 section door.
12 Tools Needed: Hammer Wood Shims Bottom Section Before installing the bottom section, the weather seal (may not be included) must be installed (see Preparing the Opening on page 10) 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. jamb header weather seal jamb level bottom section Wooden Shims 20 Please Do Not Return This Product To The Store.
13 Tools Needed: 3/16” Drill Bit Power Drill 7/16” Socket Driver Tape Measure Level Vertical Track 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. fLAGANGLE 5/16 x 1-5/8” LAG SCREWS VERTICAL TRACK ASSEMBLY Position the left hand vertical track assembly over the rollers of the bottom section.
14 Tools Needed: Power Drill 7/16” Socket Driver Stacking Sections NOTE: For door section identification see page 4. NOTE: Make sure hinges are flipped down, when stacking another section on top. 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.
15 Top Section Tools Needed: Hammer Place the top section in the opening and vertically align with lower sections. Nail Power Drill 7/16 Socket Driver Tape Measure door width +3-3/8” to 3-1/2” 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 hinge leaf against section, fastening center hinges first, and end hinges last. (Refer to Step 6).
16 Tools Needed: 9/16” Socket 7/16” Socket Ratchet Wrench 9/16” Wrench Level Hammer Flat Tip Screwdriver Attaching Adjustable Flagangle to Horizontal Track NOTE: If you have quick install flagangle, skip this step and complete Step 17. 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” large head ribbed track bolts and (2) 1/4”- 20 flange hex nuts.
Tools Needed: 9/16” Socket Ratchet Wrench 9/16” Wrench Level Hammer Attaching Quick Install Flagangle to Horizontal Track horizontal track NOTE: If quick install flagangle was installed in Step 16, skip this step and continue with Step 18. If not, complete this step. Align key slot of the horizontal track with the quick install tab of the flagangle. Push curved portion of horizontal track down to lock in place.
18 Tools Needed: 7/16” Wrench Adjusting Top Brackets HORIZONTAL track top section With tracks installed you can adjust the top brackets. Vertically align the top section with the lower sections. Once aligned, position top roller in adjustable slide against horizontal track to maintain position and tighten nut. Repeat for other side.
20 Tools Needed: DOOR IN THE UP POSITION Rear Supports WARNING Keep horizontal track parallel and within 3/4” maximum of door edge, otherwise door could fall from the horizontal position, resulting in severe injury or death. vertical TRACK vice clamps 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 the horizontal tracks are not yet supported at the rear.
21 Tools Needed: Attaching Front Sheaves Using (1) 3/8” - 16 hex nut, attach the front steel sheave in the appropriate hole (left hand shown). 3” Steel Sheave with 12” radius track: Bolt the sheave to the 13/32” hole near the top of the flagangle. 3” or 4” Steel Sheave with 15” radius track: Bolt the sheave to the first 13/32” hole in the horizontal angle. flagangle steel sheave Repeat for other side. Remove the locking pliers from the vertical tracks.
22 Tools Needed: Attaching Extension Springs 5/16”- 18 hex nut 5/16”- 18 x 3-3/4” eyebolt Position the (1) 5/16” - 18 x 3-3/4” eyebolt and (1) 5/16” - 18 hex nut in the rear support, 6” to 8” above the horizontal track. Feed the snubber cable through the rear support and tie the special knot around the “room side” of the 3 hole clip as shown. 6” - 8” horizontal track Secure the eyebolt and clip to the rear support with (1) 5/16” - 18 hex nut.
23 Tools Needed: Attaching Spring Sheaves 3/8”-16 x 1-1/4” hex head bolt steel sheave sheave fork Hook the sheave fork through the front loop of the extension spring and attach the sheave fork to the rear 3” steel sheave using (1) 3/8” -16 x 1-1/4” hex head bolt and (1) 3/8”-16 hex nut. Thread the counterbalance cable over the front sheave, around the spring sheave and tie the special knot around the “horizontal angle” 3 hole clip.
Tools Needed: Adjust counterbalance cables to create about 1” to 2” (25 mm to 50 mm) of inital spring stretch, with door in the fully open position. Measure relaxed spring length for your door height and verify with chart. Spring length must be the same for both springs to allow even door balance. Carefully remove the locking pliers from the horizontal track and lower the door into the closed position. Once the door is closed, measure the spring length in tension for both sides.
� Tools Needed: Power Drill 7/16” Socket Driver Tape Measure Side Lock 1/8” Install the side lock on the second section of the door. Secure the lock to the section with (4) 1/4”- 20 x 11/16” self drilling screws. Square the lock assembly with the door section and align with the square hole in the vertical track. The side lock should be spaced in approximately 1/8” from the section edge.
Tools Needed: WARNING OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR. FAILURE TO ADJUST OPERATOR, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY. IF YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM, THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED.
� Cleaning Cleaning Your Garage Door IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR! While factory-applied finishes on garage doors are durable, it is desirable to clean them on a routine basis. Some discoloration of the finish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of direct exposure to sunlight. Cleaning the door will generally restore the appearance of the finish.
Limited Warranty Models 8000, 8100, 8200 and 46 Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton Corp.
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.
