8000, 8100, 8200 WINDLOAD Torsion Spring Installation Instructions and Owner’s Manual Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.Wayne-Dalton.com ©Copyright 2011 Wayne-Dalton, a Division of Overhead Door Corporation 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 trained door systems technician 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...............................................................5-6 Removing The Old Door..................................... 5 Preparing The Opening..........
Package Contents NOTE: Depending on the door model, some parts listed will not be supplied if not necessary. Rear supports may or may not be included with your door.
Package Contents Continued...
Pencil Power drill Phillips head screwdriver Ratchet wrench 7/16”, 1/2” & 9/16” Socket 9/32”, 1/2”, 3/16” & 1/8” Drill bits Level Sawhorse Flat tip screwdriver Vice grips Safety glasses Tape measure 1/4” Torx bit PRE-INSTALLATION Tools Required Gloves 3/8”, 7/16” Socket driver Hammer 1/4”, 3/8”, 7/16”, 1/2” & 9/16” Wrenches Vice clamps Approved winding bars Step ladder Removing An Old Door IMPORTANT: Counterbalance SPRING TENSION Must always BE Released BEfORE any attempt IS Made TO St
Preparing the Opening Tools Needed: Recommended tools from page 5 Suitable mounting surface 2” x 6” lumber minimum Header board 2” x 6” lumber recommended If you just removed your existing door or you are installing a new door, complete all steps in PREPARING THE OPENING.
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).
3 Tools Needed: Hammer Horizontal angle Tabs Horizontal Angle 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. Hole Hole NOTE: For larger doors, a full length horizontal angle may be spot welded to the horizontal track.
5 Tools Needed: Tape Measure Installing Q.I. Jamb Brackets NOTE: The following (Q.I.) denotes a quick install jamb bracket. No additional hardware is needed. 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. Align the twistlock tab on (Q.I.
Bottom Bracket Continued... Tools Needed: 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” tamperresistant 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.
Hinge Schedule Hinges Tools Needed: Power Drill 7/16” Socket Driver 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.
9 Tools Needed: Power Drill 7/16” Socket Driver Top Bracket NOTE: Refer to illustrations (A) or (B) to determine which top bracket was supplied with your door. Follow the corresponding step below: Top 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.
Top section Bottom section U-Bar U-bar Refer to the u-bar schedule to determine the required number of u-bar(s), and placement on each section. 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 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.
11 Step Plate Tools Needed: Pencil Locate the center most stile of the bottom section of the door. Power Drill 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.
13 Bottom Section Tools Needed: Level Wood Shims 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.
Stacking Sections Tools Needed: Power Drill 7/16” Socket Driver NOTE: For door section identification see page 4. NOTE: Make sure hinges are flipped down, when stacking another section on top. Lock section 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.
16 Tools Needed: Hammer Nail Power Drill 7/16 Socket Driver Tape Measure Step Ladder Flagangle Top Section Door width +3-3/8” to 3-1/2” Place the top section in the opening and vertically align with lower sections. Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section. Flagangle Now flip up hinge leaf against section, fastening center hinges first, and end hinges last. (Refer to Step 15).
Attaching Flagangle to Horizontal Track Tools Needed: 9/16” Socket 7/16” Socket Ratchet Wrench 9/16” Wrench Level Hammer Flat Tip Screwdriver Step Ladder Flagangle NOTE: Refer to illustrations (a) or (B) to determine which horizontal track was supplied with your door. Follow the corresponding step below: 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.
Tools Needed: 7/16” Wrench 1/2” Wrench Step Ladder Tape Measure 19 Tools Needed: Step Ladder Power Drill Ratchet Wrench 7/16” Socket Driver 9/16” Socket Driver 9/16” Wrench Adjusting Top Brackets (1) 1/4” - 20 X 9/16” Track bolt and (1) 1/4” - 20 hex nut Horizontal (1) 5/16” - 18 track Nut Short shaft roller With horizontal tracks installed you can adjust the top brackets. Vertically align the top section with the lower (2) 1/4” - 20 sections.
Tools Needed: Power Drill 7/16” Socket Driver Level Tape Measure Pencil 1/4” Torx Bit Mounting surface Center Bearing Bracket Equal distance 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.
Nylon center bracket bushing Right hand wound Red winding cone Left hand side Torsion Spring Assembly Continued... Tools Needed: 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 With assistance, pick up the torsion assembly and slide one end of the tube through one end bearing bracket.
23 Tools Needed: Vice Grips 3/8” Wrench Counterbalance Cables 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.
25 Winding Torsion Spring(s) Tools Needed: Step Ladder 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. 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.
26 Tools Needed: Ratchet Wrench 1/2” Socket 1/2” Wrench (2) Vice Clamps Step ladder Rear Support Door in the up position 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. WARNING Raising door further her can result in door falling and cause severe or fatal injury.
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.
❉ Tools Needed: Power Drill 7/16” Socket Driver Tape Measure Side Lock 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. IMPORTANT: side locks must be removed or made inoperative in the unlocked position if an operator is installed on the door.
❉ Tools Needed: Tape Measure Trolley Operator 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 1. Attach operator rail to suitable mounting surface, 2 x 6 lumber minimum. 2.
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.
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.
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.
