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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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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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

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

9

4

Tools Needed:

Power Drill

7/16” Socket Driver

Sawhorses

Bottom Section U-Bar

NOTE: For door section identification see page 5.

Refer to the u-bar schedule to determine the required
number of u-bar(s), and placement on bottom
section.

Place the bottom section face down on a couple of
sawhorses or flat clean / smooth surface. Position the
u-bars according to the u-bar schedule, up against
bottom hinge leafs or just above the bottom brackets
on the bottom section. 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.

Bottom
section

U-bar

Bottom bracket

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

Door height Section Position on section

8’ 3” to 8’ 9”

9’ 0” to 10’ 6”

Bottom

10’ 9” to

12’ 3”

12’ 6” to

14’ 0”

Bottom

Top

Bottom

Top

Bottom

Top

Bottom

Top

Bottom

hinge

leaf

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

U-Bar Schedule

Windload Options Code

1100 / 1101

NA NA (1) Req. NA

NA (1) Req. (1) Req. (1) Req.

NA NA (1) Req. NA

NA (1) Req. (1) Req. NA

NA NA (1) Req. NA

NA (1) Req. (1) Req. NA

NA NA (1) Req. NA

NA (1) Req. (1) Req. NA

1102 / 1103 / 1104 /
1123 / 1124 / 1125 /

1141 / 1142

1120 / 1121 / 1122 /

1140

U-bar

1143 / 1144

10

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5

Tools Needed:

Power Drill

7/16” Socket Driver

Sawhorses

Lock/Intermediate Section U-Bar

NOTE: For door section identification see page 5.

Place the lock, intermediate I, intermediate II,
intermediate III, intermediate IV and intermediate V
sections face down on a couple of sawhorses or flat
clean/ smooth surface. Butt the top and intermediate
sections together in the proper stack sequence and
flip up the hinges.

Refer to the u-bar schedule to determine the required
number of u-bar(s), and placement on top section.

Position the u-bars according to the u-bar schedule,
and flush against the upper or lower hinge leafs.
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.

U-bar

Upper
hinge

leaf

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

End U-bar placement for lock and intermediate sections

Attaching to

center stile

U-bar

U-bar

Door height Section

8’ 3” to 8’ 9”

9’ 0” to 10’ 6”

(10’ 9” to 12’ 3”) and (12’

6” to 14’ 0”)

12’ 6” to 14’ 0” Intermediate V

Intermediate I

Intermediate II

Intermediate I

Intermediate II

Intermediate III

Intermediate I

Intermediate II

Intermediate III

Intermediate IV

Lock

Lock

Lock

U-bar

Upper hinge leaf

Lower hinge leaf

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

Center U-bar placement for lock and intermediate sections

U-Bar Schedule

Position

on

1100 / 1101 1102 1103

section

Bottom (1) Req. NA NA NA NA (1) Req. (1) Req. NA

Top NA NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req.

Bottom NA (1) Req. NA NA (1) Req. (1) Req. (1) Req. NA

Top (1) Req. NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req.

Bottom NA NA NA (1) Req. NA (1) Req. NA (1) Req.

Top (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req.

Bottom (1) Req. NA NA NA NA (1) Req. (1) Req. NA

Top NA NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom NA (1) Req. NA NA (1) Req. (1) Req. (1) Req. NA

Top (1) Req. NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom NA NA NA NA NA (1) Req. NA NA

Top NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom (1) Req. NA NA (1) Req. (1) Req. (1) Req. (1) Req. NA

Top NA NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom (1) Req. NA NA NA NA (1) Req. (1) Req. NA

Top NA NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom NA (1) Req. NA NA (1) Req. (1) Req. (1) Req. NA

Top (1) Req. NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom NA NA NA NA NA (1) Req. NA NA

Top NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom (1) Req. NA NA (1) Req. (1) Req. (1) Req. (1) Req. NA

Top NA NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom NA (1) Req. NA NA NA (1) Req. (1) Req. NA

Top (1) Req. NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Bottom NA NA NA NA (1) Req. (1) Req. (1) Req. NA

Top NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. (1) Req. NA

Windload Options Code

1104 / 1120 /

1121

1122 / 1123 /

1124 / 1141

1125 / 1142 1140 1143 / 1144

INSTALLATION

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11

6

Top Section U-Bar

Tools Needed:

Power Drill

7/16” Socket Driver

Sawhorses

NOTE: For door section identification see page 5.

Place the top and intermediate sections face down on
a couple of sawhorses or flat clean/ smooth surface.
Butt the top and intermediate sections together in the
proper stack sequence and flip up the hinges.

Refer to the u-bar schedule to determine the required
number of u-bar(s), and placement on top section.

Position the u-bar either up against top bracket
assembly, align top edge of u-bar with top edge of
top section, or up against upper hinge leafs. 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.

NOTE: If you have windload codes 1100 and 1101
the u-bar is positioned below the top bracket
assembly.

NOTE: For windload codes other than 1100 and
1101 the u-bar is positioned above the top bracket
assembly.

U-bar

Top bracket

assembly

Top

section

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

Windload codes: 1100/1101

Top section

U-bar

Top bracket

assembly

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

Door height Section Position on section

8’ 3” to 8’ 9”

9’ 0” to 10’ 6”

Top

10’ 9” to

12’ 3”

12’ 6” to

14’ 0”

Bottom

Top

Bottom

Top

Bottom

Top

Bottom

Top

Other Windload codes

Bottom of

top section

U-bar

Upper hinge

leaf

(2) 1/4”- 14 x 7/8”

Self drilling screws

Bottom of top section

U-Bar Schedule

Windload Options Code

1100 / 1101 1102

NA NA NA (1) Req. (1) Req. NA

NA (1) Req. (1) Req. (1) Req. (1) Req. (1) Req.

NA (1) Req. NA NA (1) Req. NA

(1)*Req. NA (1) Req. (1) Req. (1) Req. NA

NA NA NA (1) Req. (1) Req. NA

NA (1) Req. (1) Req. (1) Req. (1) Req. NA

(1) Req. NA NA NA (1) Req. NA

NA NA (1) Req. (1) Req. (1) Req. NA

1103 / 1104 /

1120 / 1121

1122 / 1123 /

1124 / 1141

1125 / 1140 /

1142

1143 / 1144

Intermediate

section

12

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7

Step Plate

Bottom section

Tools Needed:

Pencil

Power Drill

5/16” Drill Bit

7/16” Wrench

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 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.

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

Bottom section

Step plate

8” Max mounting

height

(2) 1/4”-20

Flange hex nuts

Inside step plate

8” Max mounting

height

(2) 1/4 x 2-3/4” Carriage bolts

Outside step plate

Step plate assembly

Step plate assembly

Bottom section

Bottom section

INSTALLATION

Enlarge holes on

8

Tools Needed:

Tape Measure

Pencil

Power Drill

9/32” Drill Bit

1/2” Drill Bit

7/16” Wrench

Lift Handle

NOTE: Doors with a keyed lock do not require this

lift handle.

NOTE: For door section identification see page 5.

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.

Vertical align the lift handle, use the lift handle as a
template and mark the hole locations on the section.

Drill (2) 9/32” dia. holes through section. Enlarge the
holes from outside the door to 1/2” dia.

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.

NOTE: Do not drill through or enlarge holes on the
inside of the door.

outside of section to

1/2” diameter.

Bottom
Section

Lift handle outside

9/32” Diameter

holes (do not

enlarge holes).

4”

(2) Spacers

Lock section

Lift handle

(2) 1/4” x 2-1/2”

Carriage bolts

Lock

section

Lock Section

Vertically

aligned

Bottom section

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 inside

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Lift handle

(2) 1/4”-20

Hex nuts

Bottom section

13

9

Tools Needed:

Level

Wood Shims

Bottom Section

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.

Jamb

Weather seal

Level

Bottom
section

10

Tools Needed:

Power Drill

3/16” Drill Bit

7/16” Socket Driver

Level

Tape Measure

Step Ladder

7/16” Wrench

Flat tip screwdriver

Vertical Track Assembly

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.

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. Loosely fasten the vertical track assembly
to the jamb using 5/16” x 1-5/8” lag screws. Tighten
bottom lag screw securing vertical track assembly to
jamb, to maintain 5/8” spacing. Repeat for the right
hand side.

Loosen the 1/4” - 20 x 9/16” track bolts and 1/4”

- 20 nuts of each clip plates. The vertical track
assemblies will be adjusted and tightened in Step 13.

Hang counterbalance cables over vertical track
assemblies.

Vertical track
assembly

Vertical
track

5/16” X 1-5/8”
Lag screws
(your number of
lag screws may
vary)

Wooden

shims

Clip plate

5/16” X 1-5/8”
Lag screws

Clip mount (your clip
mount quantity and
location may vary)

Vertical track

1/4” - 20 X 9/16”
Track bolt and
1/4” - 20 nut

Vertical

track

assembly

Bottom
section

Bottom
section

Roller

5/8”

14

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11

Stacking Sections

Tools Needed:

Power Drill

7/16” Socket Driver

NOTE: For door section identification see page 5.

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.

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 single end hinges: flip end hinge leaf upward
and fasten the hinge to the above section with (4)
1/4”-14 x 7/8” self tapping screws. Repeat for the
right hand end hinge(s).

For double end hinges: flip up both end hinge leafs
and secure the hinges to the above section with (6)
1/4”-14 x 7/8” self tapping screws. Repeat for the
right hand end hinge(s).

Repeat for other sections except the top section.

NOTE: Install lock at this time (sold separately). See
side lock instructions on page 25.

Lock

section

Section

Hinge

leaf

(2) 1/4” - 14 x 7/8”

Self drilling screws

INSTALLATION

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

Center hinge

Hinge

leaf

Section

Single end hinge

Hinge leafs

Section

(6) 1/4” - 14 x 7/8”
Self drilling screws

Double end hinge

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15

12

Tools Needed:

Hammer

Nail

Power Drill

7/16 Socket Driver

Tape Measure

Step Ladder

7/16” Wrench

Flat tip screwdriver

Top Section

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 section and bending
it over the top section.

Now flip up hinge leaf, hold tight against section and
fasten center hinges first, and end hinges last. (Refer
to Step 11).

Position vertical track assemblies between 1-11/16”
(43 mm) to 1-3/4” (44 mm) from the edge of the
door. Tighten the bottom lag screw. Vertical track
assemblies must be parallel to the door section.

Repeat for opposite side.

IMPORTANT: THE DIMENSION BETWEEN THE
VERTICAL TRACK ASSEMBLIES MUST BE DOOR
WIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR
SMOOTH, SAFE DOOR OPERATION.

Complete the vertical track installation by tightening
all 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.

Vertical track

assembly

Door width

+3-3/8” to 3-1/2”

Vertical track

assembly

Repeat for opposite side.

Vertical track

Nail

Roller

Top section

Roller against
vertical track

1-11/16” To 1-3/4”

Vertical track

assembly

Top section

16

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13

Attaching Adjustable Horizontal

Track

Vertical
track
assembly

Tools Needed:

9/16” Socket
7/16” Socket

Ratchet Wrench

9/16” Wrench

Level

Hammer

Flat Tip
Screwdriver
Step Ladder

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 vertical track assembly with (2) 1/4”-20 x
9/16” track bolts and (2) 1/4” - 20 flange hex nuts.

WARNING

DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS
ARE SE CURED AT REAR, AS OUTLINED IN STEP 23,
OR DOOR COULD FALL FROM OVERHEAD POSI TION
CAUSING SEVERE OR FATAL INJURY.

Level the horizontal track and bolt the horizontal
angle to the slot in the vertical track assembly 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 12.

IMPORTANT: FAILURE TO REMOVE NAIL BEFORE
ATTEMPTING TO RAISE DOOR COULD CAUSE
PERMANENT DAMAGE TO TOP SECTION.

(1) 3/8”- 16

Hex nut

1/4” - 20 x 9/16”

Track bolts

1/4” - 20 Flange

hex nuts

Vertical

track

assembly

(1) 3/8”- 16 X 3/4”

Truss head bolt

Horizontal angle

INSTALLATION

roller

(2) 1/4” - 20

flanged hex nuts

Horizontal

track

(A)

1/4” - 20 X 9/16” Track bolts
and 1/4” - 20 flanged hex nut(s)

Top bracket

slide

Horizontal

track

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

(B)

14

Tools Needed:
7/16” Wrench

1/2” Wrench
Step Ladder

Adjusting Top Brackets

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 top bracket (A): Maintaining the slide(s) position,
tighten the (2) 1/4” - 20 flange hex nuts.

For top bracket (B): Maintaining the slide(s) position,
tighten the (1) 5/16” - 18 nut(s) to secure the slide(s)
to the top bracket base(s). Now lock each 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 slides.

NOTE: If you have windload option codes 1124, 1125,
1142, or 1144: (2) slides are required to be adjusted
and tightened on each end of section.
Repeat for other side.

Correct

section

Top bracket assembly
(only for windload
option codes 1124,
1125, 1142 and

1144)

Incorrect

Top

Top bracket

Top section

Long or

short shaft

roller

Top bracket

slide

Short shaft

slide

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17

15

Pushnuts

Tools Needed:
Tape Measure

Step Ladder

NOTE: If you have windload option codes 1121,
1122, 1123, 1124, 1125, 1141 and 1142, pushnuts
are required. If not, skip this step and continue with
step 16.

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.

Repeat same process for the end hinges on the left
hand side of door, then repeat same process for other
side of door.

1/4” spacing

Top bracket

assembly

Pushnut

Roller

stem

End Hinge

1/4” spacing

Pushnut

Roller

stem

16

Tools Needed:

Power Drill

7/16” Socket Driver

9/16” Socket

Ratchet Wrench

9/16” Wrench

Step Ladder

Torsion End Bearing Brackets

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS

DETERMINED FROM INSIDE THE BUILDING LOOKING
OUT.

End bearing brackets are right and left. 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 (3) 5/16” x 1-5/8” lag screw. Repeat for other
side.

(2) 3/8”-16

Nuts

Horizontal

angle

(3) 5/16” x 1-5/8”

Lag screws

Left end

bearing bracket

Upper slots used
on 15” radius
track
Lower slots used
on 12” radius
track

(2) 3/8”-16 x 3/4”

Truss head bolts

Left end

bearing bracket

18

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17

Torsion Spring Assembly

Tools Needed:

Step Ladder

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS
DETERMINED FROM INSIDE THE BUILDING LOOKING
OUT.

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. 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.

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.

Slide the center bearing bracket onto the torsion
tube followed by the springs and cable drums.
Center bearing bracket, springs and cable drums
must be positioned, as shown. With assistance, pick
up the torsion assembly and slide one end of the
tube through one end 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.

Left hand

cable

drum red

RIGHT HAND
WOUND RED

WINDING CONE

LEFT HAND

SIDE

Center bearing

LEFT HAND
WOUND BLACK
WINDING CONE

RIGHT HAND SIDE

bracket

Torsion tube

Center bearing

bracket

Right hand

cable drum

black

Right hand
cable drum

black

INSTALLATION

Left hand cable

drum red

Right hand wound
Red winding cone

Left hand side

Equal

spacing

Torsion

assembly

Torsion tube

Center

bracket

End bearing

Left hand wound

Black winding cone

right hand side

bracket

Torsion

assembly

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19

18

Tools Needed:

Power Drill

7/16” Socket Driver

Level

Tape Measure

Pencil

1/4” Torx Bit

Step Ladder

Center Bearing Bracket

NOTE: For clarity the torsion counterbalance assembly

is not shown.

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.

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.

IMPORTANT: USE THE 5/16” X 1 5/8” TAMPER­RESISTANT 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.

Center of end

bearing bracket

Mounting
surface

(1) 5/16” x 1-5/8”
Lag screw

Horizontal line

Mounting surface

Horizontal

line

Center bearing

bracket

Equal

distance

Vertical

line

Vertical

line

Center bearing

bracket

19

Tools Needed:

9/16” Socket

Ratchet Wrench

9/16” Wrench

Step Ladder

Torsion Spring(s) Installation

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.

IMPORTANT: SPRINGS UNDER TENSION CAN BE
DANGEROUS.

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
REPLACEMENTS.

spring cone

Torsion

spring

(1) 3/8”-16 Nut

(1) 5/16” x 2”

Tamper-resistant lag screw or

(1) 5/16” x 1-5/8” lag screw

Center bearing

Stationary

bracket

Center bearing bracket

(1) 5/16” x 1-5/8”
Lag screw

Torsion spring

Stationary

spring cone

Spring warning tag

(1) 3/8”-16 x 1-1/2”
Hex head bolt

Torsion

spring

(1) 3/8”-16 Nut

(1) 3/8”-16 x 1-1/2”
Hex head bolt

20

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Torsion

spring

20

Tools Needed:

Vice Grips

3/8” Wrench

Step Ladder

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. Attach vice grips to torsion tube and brace vice
grips against jamb to keep cable taunt.

Left cable drum

Cable

Cable

hooked in

cable drum

21

Tools Needed:

(2) Vice Clamps

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.

IMPORTANT: CHECK EACH CABLE, MAKING SURE
BOTH ARE SEATED PROPERLY ON THE CABLE
DRUMS AND HAVE EQUAL CABLE TENSION.

Securing Door

for Spring Winding

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.

Left end
bearing
bracket

Cable in
position

Set

screws

Vice

grips

Jamb

Left cable

drum

Torsion

tube

INSTALLATION

WARNING

FAILURE TO PL ACE 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

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21

22

Winding Torsion Spring(s)

Tools Needed:

Approved Winding Bars

Step Ladder
3/8” Wrench

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.

Check the label attached to the spring warning tag
for the required number of complete turns to balance
your door.

8’3” Door Height = Approx. 8-7/8 Turns
8’6” Door Height = Approx. 9-1/8 Turns
8’9” Door Height = Approx. 9-3/8 Turns
9’0” Door Height = Approx. 9-5/8 Turns
9’3” Door Height = Approx. 9-3/4 Turns
9’6” Door Height = Approx. 10 Turns
9’9” Door Height = Approx. 10-1/4 Turns
10’0” Door Height = Approx. 10-1/2 Turns
10’3” Door Height = Approx. 10-3/4 Turns
10’6” Door Height = Approx. 11 Turns
10’9” Door Height = Approx. 11-1/8 Turns
11’0” Door Height = Approx. 11-3/8 Turns
11’3” Door Height = Approx. 11-5/8 Turns
11’6” Door Height = Approx. 11-7/8 Turns
11’9” Door Height = Approx. 12-1/8 Turns
12’0” Door Height = Approx. 12-3/8 Turns
12’3” Door Height = Approx. 9-5/8 Turns
12’6” Door Height = Approx. 9-3/4 Turns
12’9” Door Height = Approx. 10 Turns
13’0” Door Height = Approx. 10-1/8 Turns
13’3” Door Height = Approx. 10-1/4 Turns
13’6” Door Height = Approx. 10-1/2 Turns
13’9” Door Height = Approx. 10-5/8 Turns
14’0” Door Height = Approx. 10-7/8 Turns

Torsion

tube

Winding

cone

Spring

Spring warning

tag(s)

Approved

winding bars

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.

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).
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 locking clamps from the torsion tube and
the vertical tracks.
IMPORTANT: CAUTIOUSLY REMOVE LOCKING PLIERS
FROM THE TORSION TUBE AND LOCKING CLAMPS
FROM 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.

22

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Set

screws

Torsion

tube

Winding

cone

Approved

Winding bars

Spring

23

Door in the up position

Rear Support

Tools Needed:

Ratchet Wrench

1/2” Socket

1/2” Wrench

(2) Vice Clamps

Step Ladder

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.

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.

WARNING

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.
NOTE: 26” angle 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
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.
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.

3/4”

(3) 5/16”-18 x 1-1/4”

Hex bolts and (3) 5/16”­18 nuts

clamps

Horizontal track

Door edge

Perforated angle

(3) 5/16”-18

Nuts

Vertical

track

Vice

3/4”

INSTALLATION

Weather

seal

Jamb

PERMANENTLY ATTACHED WEATHER

SEAL

Intermediate

section

Windload

label

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23

Rear Support Continued...

Sound framing

members

Tools Needed:

Push upward on the winding bar while carefully
loosening the set screws in the winding cone. BE
PREPARED TO SUPPORT THE FULL FORCE OF THE
TORSION SPRING ONCE THE SET SCREWS ARE
LOOSE.

Carefully adjust spring tension 1/4 turn. Retighten
both set screws in the winding cone and repeat
for the other side. RECHECK DOOR BALANCE DO
NOT ADJUST MORE THAN 1/2 TURN FROM THE
RECOMMENDED NUMBER OF TURNS.

If door still does not balance correctly, contact a
qualified door agency. If the door still does not
operate easily, lower the door into the closed position,
UNWIND THE SPRING(S) FULLY (Reference the insert
“Removing The Old Door/Preparing The Opening”
section on torsion spring removal), and recheck the
following the items:

1.) Check the door for level.

2.) Check the torsion tube for level.

3.) Check the track spacing.

4.) Check the counterbalance cables for equal
tension.

5.) Check the track for potential obstruction of the
rollers.

6.) Clamp locking pliers onto track and rewind
springs.

IMPORTANT: IF DOOR STILL DOES NOT OPERATE
PROPERLY, THEN CONTACT A TRAINED DOOR SYSTEM
TECHNICIAN.

Horizontal
track

Horizontal

track

Perforated angle

Perforated angle - bolted using (2)

5/16” x 1-5/8” hex head lag screws

to ceiling member and parallel to

24”

Bolt must extend into the track

to serve as a roller stop

width of door. Space lag screws no

further than 24” apart.

Bolt must extend into

the track to serve as a

roller stop

Sound framing members

Perforated angle

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.

24

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❉

❉

Side Lock

Tools Needed:

Power Drill

7/16” Socket Driver

Tape Measure

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.

NOTE: After completing this step, continue with Step
12 on page 16.

(4) 1/4”- 20 X 11/16”

self drilling screws

1/8”

Tools Needed:

Power Drill

Drill Bit

Pull Rope

WARNING

DO NOT INSTALL PULL ROPES ON DOORS WITH
ELECTRIC OPERATORS. CHILDREN MAY BECOME
ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL
INJURY.

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.

No. 6
screw eye

Pull rope

OPTIONAL INSTALLATION

Bottom
bracket

Pull rope

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25

❉

❉

Cleaning

CLEANING AND PAINTING INSTRUCTIONS FOR DOORS

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.

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.

26

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

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, for a period of TEN (10) YEARS from the date of installation against:

(i) The door becoming inoperable due to rust-through of the steel skin from the core of the door section, due to cracking, splitting, or other
deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.

(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, for a period of TEN (10) YEARS from the
date of installation, 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.

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

MAINTENANCE

27

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

Thank you for your purchase

28