Wayne-Dalton 8000, 8200, 8100 User Manual

8000, 8100, 8200 Windload, Light
Commercial

Torsion Spring

Installation Instructions and Owner’s Manual

IMPORTANT NOTICE!

Wayne-Dalton, a Division of
Overhead Door Corporation
P.O. Box 67, Mt. Hope, OH 44660
www.Wayne-Dalton.com

©Copyright 2011 Wayne-Dalton, a Division of Overhead Door Corporation Part No. 335381 REV3 08/18/2011

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.

Table of Contents

Important Safety Instructions ............................................ 2

Package Contents ..........................................................3-4

Tools Required .................................................................. 4

Door Section Identification ................................................ 5

WARNING

TO AVOID POSSIBLE INJURY, READ
THESE INSTRUCTIONS CAREFULLY
BEFORE ATTEMPTING INSTALLATION.

Pre-Installation ..............................................................5-6

Removing The Old Door .................................... 5

Preparing The Opening ..................................... 6

Installation ..................................................................7-24

Optional Installations ...................................................... 25

Side Lock .......................................................25

Pull Rope ........................................................ 25

Maintenance ................................................................... 26

Cleaning ......................................................... 26

Painting Instructions ....................................... 26

Warranty ......................................................................... 27

Dealer Locator Information.............................................. 28

Definition of key words used in this manual:

WARNING

INDICATES A POTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, COULD
RESULT IN SEVERE OR FATAL INJURY.

CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT
FROM FAILURE TO FOLLOW INSTRUCTIONS.

IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER
DOOR OPERATION.

NOTE: Information assuring proper installation of the door.

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.

1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

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

3. It is always recommended to wear eye protection when using tools,
otherwise eye injury could result.

4. Avoid installing your new door on windy days. Door could fall during
the installation causing severe or fatal injury.

5. Doors 12’- 0” wide and wider should be installed by two persons, to
avoid possible injury.

6. Operate door ONLY when it is properly adjusted and free from
obstructions.

7. If a door becomes hard to operate, inoperative or is damaged,
immediately have necessary adjustments and/or repairs made
by a trained door system technician using proper tools and
instructions.

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

9. DO NOT place fingers or hands into open section joints when closing a
door. Use lift handles/gripping points when operating door manually.

10. DO NOT permit children to operate garage door or door controls.
Severe or fatal injury could result, should the child become entrapped
between the door and the floor.

11. Due to constant extreme spring tension, DO NOT attempt any
adjustment, repair or alteration to any part of the door, especially
to springs, spring brackets, bottom corner brackets, red colored
fasteners, cables or supports. To avoid possible severe or fatal injury,
have any such work performed by a trained door systems technician
using proper tools and instructions.

12. On electrically operated doors, pull down ropes must be removed and
locks must be removed or made inoperative in the open (unlocked)
position.

13. Top section of door may need to be reinforced when attaching
an electric opener. Check door and/or opener manufacturer’s
instructions.

14. VISUALLY inspect door and hardware monthly for worn and or broken
parts. Check to ensure door operates freely.

15. Test electric opener’s safety features monthly, following opener
manufacturer’s instructions.

16. NEVER hang tools, bicycles, hoses, clothing or anything else from
horizontal tracks. Track systems are not intended or designed to
support extra weight.

After installation is complete, fasten this manual

near garage door.

2

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yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

Package Contents

Door sections (as required)

(1) Torsion tube

(2) Horizontal tracks RH/LH

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.

U-bar’s

(as required)

Weather seal & nails

(if included)

(1) Center bracket

(2) Step plates

Top bracket assembly

(as required)

Left and right bottom

brackets

Left and right end

bearing brackets

#6 Screw eye and

pull rope

(if included)

Right and left

counterbalance cables

Extension brackets

(as required)

Left and right cable
drums (as required)

(2) Lift handles &

spacers

(2) Cotter pin

Long and short shaft rollers

(As required)

Right and left torsion
springs (as required)

1

#1, #2, #3, #4, #5,

#6 & #7 hinges

(as required)

(2) RH/LH Vertical track

assemblies

(1) Windload label

Top bracket assemblies

(as required)

Pushnuts

(as required)

(2) Roller Spacers

(2) Flat Washer(2) Clevis pin

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3

Package Contents Continued...

(2) 1/4”- 20 Hex

nuts

5/16” x 1 5/8” Hex head lag screws

(as required)

5/16” x 1 5/8” Tamper resistant lag screw

(as required)

1/4”- 20 Flange hex nuts

(as required)

(2) 1/4” x 2- 1/2” Carriage bolts

Tools Required

(2) 3/8”- 16

Hex nuts

1/4”- 20 x 9/16” Track Bolts

(as required)

(2) 3/8”- 16 x 1-1/2” Hex head

bolts

5/16”- 18 Hex nuts

(as required)

(2) 3/8” - 16 x 3/4”

Truss head bolts

5/16” x 2” Tamper-resistant hex head lag

(2) 1/4” x 2-3/4” Carriage bolts

1/4” - 14 x 7/8” Self drilling

screws (as required)

(2) 1/4”- 20 X 5/8” Tamper

resistant screws

screws (as required)

Power drill

Phillips head screw-

driver

Sawhorse

Pencil

7/16”, 1/2” & 9/16”

Socket

Flat tip screwdriver

Ratchet wrench

9/32”, 1/2”, 3/16” & 1/8” Drill

bits

Vice grips

Safety glasses

Tape measureLevel Vice clamps

1/4” Torx bit

3/8”, 7/16” Socket driver

1/4”, 3/8”, 7/16”, 1/2” &

9/16” Wrenches

Approved winding bars

Gloves

Hammer

Step ladder

4

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Door Section Identification

WARNING LABEL

INTERMEDIATE

I SECTION

18”

BOTTOM BRACKET WARNING LABELS

or

21”

BOTTOM SECTION

ASTRAGAL

Door

Height

10’0” 21” 21” 21” 18” 18” NA NA 21”

10’3” 21” 21” 21” 21” 21” NA NA 18”

10’6” 21” 21” 21” 21” 21” NA NA 21”

10’9” 21” 18” 18” 18” 18” 18” NA 18”

11’0” 21” 18” 18” 18” 18” 18” NA 21”

11’3” 21” 21” 18” 18” 18” 18” NA 21”

11’6” 21” 21” 21” 18” 18” 18” NA 21”

11’9” 21” 21” 21” 21” 18” 18” NA 21”

12’0” 21” 21” 21” 21” 21” 21” NA 18”

12’3” 21” 21” 21” 21” 21” 21” 21” 21”

12’6” 21” 18” 18” 18” 18” 18” 18” 21”

12’9” 21” 21” 18” 18” 18” 18” 18” 21”

13’0” 21” 21” 21” 18” 18” 18” 18” 21”

13’3” 21” 21” 21” 21” 18” 18” 18” 21”

13’6” 21” 21” 21” 21” 21” 18” 18” 21”

13’9” 21” 21” 21” 21” 21” 21” 21” 18”

14’0” 21” 21” 21” 21” 21” 21” 21” 21”

Bottom Lock (second)

8’3” 21” 21” 18” 18” NA NA NA 21”

8’6” 21” 21” 21” 21” NA NA NA 18”

8’9” 21” 21” 21” 21” NA NA NA 21”

9’0” 18” 18” 18” 18” 18” NA NA 18”

9’3” 21” 18” 18” 18” 18” NA NA 18”

9’6” 21” 18” 18” 18” 18” NA NA 21”

9’9” 21” 21” 18” 18” 18” NA NA 21”

Intermediate I

(third)

Intermediate II

(fourth)

Intermediate III

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.

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

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.

(fifth)

Intermediate IV

(sixth)

Intermediate V

(seventh)

PRE-INSTALLATIONPRE-INSTALLATION

Top

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 Wayne­Dalton, a Division of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH 44660, or at www.Wayne-Dalton.com.

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 to the Find a Dealer section online at www.Wayne-Dalton.com

5

Preparing the Opening

If you just removed your existing door or you are installing a new door, complete all steps in
PREPARING THE OPENING.

To ensure secure mounting of track brackets, side and center bearing brackets, or steel angles
to new or retro-fit construction, it is recommended to follow the procedures outlined in DASMA
Technical Data Sheets #156, #161 and #164 at www.dasma.com.

The inside perimeter of your garage door opening should be framed with wood jamb and header
material. The jambs and header must be securely fastened to sound framing members. It is
recommended that 2” x 6” lumber be used. The jambs must be plumb and the header level.
The jambs should extend a minimum of 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).

IMPORTANT: CLOSELY INSPECT EXISTING JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD
FOUND NOT TO BE SOUND, MUST BE REPLACED.

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.

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

Suitable mounting surface
2” x 6” lumber minimum

Plumb
jambs

Headroom

Header

Level

header

Door width

Header board
2” x 6” lumber
recommended

Door

height

Backroom

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.

Weather Seal (May Not Be Included):
Cut the weather seal if necessary to fit the header and jambs.

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.

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: Backroom is defined as the distance needed from the opening back
into the garage to allow the door to open fully.

NOTE: For door heights from 10’1” to 14’0”, refer to your operator manufacture installation
instructions for appropriate depth into room.

Jamb

Weather

seal

Jamb

Weather
seal

Jamb

WEATHER SEAL

TRACK TYPE Torsion

12” 12 1/2”

15” 14 1/2”

HEADROOM REQUIREMENT

DOOR HEIGHT TRACK

8’3” - 9’0” 12”, 15” Radius 126” 168”

9’3” - 10’0” 12”, 15” Radius 138” 168”

10’1” - 12’0” 12”, 15” Radius 162” -

12’1” - 14’0” 12”, 15” Radius 186” -

BACKROOM REQUIREMENT

MANUAL

LIFT

MOTOR

OPERATED

6

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yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

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 (NOT SUPPLIED) 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.
IMPORTANT: WHEN INSTALLING 5/16” DIAMETER LAG SCREWS USING AN ELECTRIC DRILL/DRIVER, THE DRILL/DRIVER’S CLUTCH MUST BE SET TO DELIVER NO MORE THAN
200 IN. LBS. OF TORQUE. FASTENER FAILURE COULD OCCUR AT A HIGHER SETTING.

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.

1

Tools Needed:

Power Drill

7/16” Socket Driver

Pliers

1/4” Torx bit

Bottom Bracket

NOTE: For door section identification see page 5.

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.
IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS
DETERMINED FROM INSIDE THE GARAGE LOOKING
OUT.
Locate the bottom section, attach the left hand
bottom bracket to the end stile using (4) 1/4”-14
x 7/8” self drilling screws and (1) 1/4”-14 x 5/8”
tamper-resistant self drilling screw as shown. Repeat
for other side.
NOTE: All doors are provided with the tamper
resistant fastener 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.
Refer to the u-bar schedule (bottom of page) to
determine if the bottom section requires a u-bar.
U-bar attachment (if required): Position the u-bar
over the bottom brackets and center the u-bar side
to side on the bottom section. Secure the u-bar to the
bottom section using (2) 1/4”-14 x 7/8” self drilling
screws at each end and center stile location(s).
NOTE: If you have windload specification option
codes 1124, 1125, 1142 and 1144: Extension
brackets and long shaft rollers 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 shaft 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.
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.

Left hand

bottom

bracket

End Stile

Warning label

Bottom
bracket

Cotter Pin

Washer

(1) 1/4”- 14 x 7/8”

Self drilling or (1) 1/4”- 14 x 5/8”

tamper-resistant screw

Bottom
section

Warning

Short or long

shaft roller

(only windload

option codes

1124/1125/1142

and 1144 use long

shaft rollers)

Bottom

Bracket

Hinge tubes of

bottom bracket

Spacer

label

Counterbalance

cable

Clevis Pin

(4) 1/4”- 14 x 7/8”
Self drilling screws

INSTALLATION

U-bar (if required)

(2) 1/4”- 14 x 7/8”
Self drilling screws

Stile

U-bar (if required)

(2) 1/4”- 14 x 7/8”
Self drilling screws

Hinge tube of

extension bracket

(if required)

U-Bar Schedule

Door height Section

8’ 3” to 8’ 9”

9’ 0” to 10’ 6” NA (1) Req.

10’ 9” to 12’ 3” NA (1) Req.

12’ 6” to 14’ 0” NA (1) Req.

Bottom Bottom

Position

on

section

Windload Option codes

1143/1144

(1) Req. (1) Req.

1104/1123/1124/1125/

1141/1142

Astragal

Bottom section

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7

2

Tools Needed:

Power Drill

7/16” Socket Driver

Hinges

NOTE: Refer to the door section identification on page

5 to determine your lock (second), intermediate I
(third), intermediate II (fourth), intermediate III (fifth),
intermediate IV (sixth), intermediate V (seventh) and
top sections. Measure your sections to make sure
they are the correct height as indicated on the chart.

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.

1

2

3

4

5

6

1

7

#1 End and center hinge

Roller

placement

Typical hinge

stamping location

Roller

placement

2

#2 Thru #7 End hinges

Typical hinge

stamping location

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.

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.

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.

Repeat for all other sections using #2 end hinges
second section (lock section), or the #3 end hinges
third section (intermediate section), or the #4 end
hinges fourth section (intermediate section II), or
the #5 end hinges fifth section (intermediate section
III), or the #6 end hinges sixth section (intermediate
section IV), or the #7 seventh section (intermediate
section V) of the door.

NOTE: If you have windload option codes 1124, 1125,
1142, or 1144: Double end hinges and long shaft
roller are required on each end of each section.

IMPORTANT: WHEN PLACING ROLLERS INTO END
HINGES NUMBER 2 AND HIGHER, THE ROLLER GOES
INTO TUBE FURTHEST AWAY FROM SECTION.

7

6

5

4

3

2
1

END STILE HOLE

PATTERN (LEFT SIDE

IS SHOWN. RIGHT

SIDE IS OPPOSITE.)

Pre-punched holes

in center stile

Short shaft

roller

End stile

End hinge

#1

#4

Single end hinge

1

(2) 1/4”- 14 x 7/8”
Self drilling screws

(2) 1/4”- 14 x 7/8”
Self drilling screws

End hinge

1

Center

hinge

1

(2) 1/4”- 14 X 7/8”
Self drilling screws

Center

stile

Center hinge

Previously installed

end hinge

Long shaft roller

Stile

Double end hinge

8

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3

Top Bracket

Tools Needed:

Power Drill

7/16” Socket Driver

7/16” Wrench

NOTE: For door section identification see page 5.

NOTE: Refer to illustrations (A) or (B) to determine

which top bracket was supplied with your door.
Follow the corresponding step below:

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 8). 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.

Insert a short shaft roller into the top bracket slide.
The top bracket slide will be adjusted and tightened
in Step 14. Repeat for the opposite side.

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 8). Ensure the top
bracket base assembly is level and aligned with the
edge of the section. Secure the top bracket assembly
to the endstile using (4) 1/4” - 14 x 7/8” self drilling
screws. Loosen the 5/16” - 18 nut on the top bracket
assembly. Insert a short shaft roller into the top
bracket slide. The top bracket slide will be adjusted
and tightened in Step 15. Repeat for the opposite
side.

NOTE: For windload specification option codes 1124,
1125, 1142 and 1144, do not insert a short shaft
roller.

NOTE: If you have windload specification option
codes 1124, 1125, 1142 and 1144: Two top bracket
assemblies and a long shaft roller are required
(C). 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 shaft 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 slides will be adjusted and tightened in Step

14. Repeat for other side.

(2) 1/4”-20

Flange hex

s

nut

Top bracket

slide

Short stem

roller

#6 hole

bracket

assembly

End
stile

Top

End
stile

(A)

Top

section

Self drilling screws

Center

hole

Top bracket

base

Center hole

INSTALLATION

(4) 1/4”- 20 x 7/8”

Top

section

(1) 5/16”- 18 x 5/8”
Carriage bolt and (1)
5/16”- 18 hex nut

(4) 1/4”- 14 x 7/8”

Short shaft

roller

(B)

Stile

Top bracket

(1) 5/16”- 18 x
5/8” Carriage bolt
and (1) 5/16”- 18
hex nut

Long shaft roller

(1124 / 1125 /

1142 / 1144 only)

(C)

Self drilling screws

assembly

(1) 5/16”- 18 x 5/8”

Carriage bolt and (1)

5/16”- 18 hex nut

(4) 1/4”- 14 x 7/8”

Self drilling screws

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 to the Find a Dealer section online at www.Wayne-Dalton.com

9