Wayne-Dalton 8200, 8100, 8000 User Manual

8000, 8100, 8200 WINDLOAD

Torsion Spring

Installation Instructions and Owner’s Manual

IMPORTANT NOTICE!

Read these instructions carefully before attempting

Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.Wayne-Dalton.com

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

Door Section Identiﬁcation ................................................ 4

Tools Required .................................................................. 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 ..................................................................7-25

Optional Installations .................................................26-27

Side Lock .......................................................26

Pull Rope ........................................................ 26

Trolley Operator .............................................. 27

Maintenance ..............................................................28-29

Cleaning ......................................................... 28

Painting Instructions ....................................... 29

Warranty ......................................................................... 30

Dealer Locator Information.............................................. 30

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.

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

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.

(2) Quick Install RH/LH

ﬂagangles

U-Bar’s

(as required)

(2) Fully adjustable

RH/LH ﬂagangles

Top bracket assemblies

(as required)

Door sections (as required)

(1) Torsion tube

(2) Horizontal tracks RH/LH

Top bracket assemblies

(as required)

#1, #2, #3 and

#4 Wide hinges

(as required)

Horizontal angles RH/LH

(as required)

#1, #2, #3 and #4

Narrow hinges

(as required)

Weather seal & nails

(if included)

(1) Center bracket (1) Center bracket

(2) Step plates

Left and right bottom

brackets (as required)

End bearing bracket

#6 Screw eye and

pull rope

(if included)

Extension brackets

(as required)

bushing

(2) Lift handles &

spacers

Long and short stem rollers

(as required)

Right & left torsion

springs (as required)

(1) Windload label

Q.I. jamb brackets

(as required)

Right and left

counterbalance cables

Right & left

Drums

(2) Roller Spacers

Slotted jamb brackets

(as required)

(2) Vertical

RH/LH tracks

Left and right bottom

brackets (as required)

Pushnuts

(as required)

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

Package Contents Continued...

(2) 1/4”- 20 Hex

nuts

5/16” x 1 5/8” Hex head lag screws

5/16” x 1 5/8” tamper resistant Lag Screw

1/4”- 20 Flange hex nuts

(as required)

(2) 1/4” x 2- 1/2” carriage bolts

Door Section Identification

(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)

Cotter pins

(as required)

5/16” Washers

(as required)

(2) 1/4” x 2-3/4” carriage bolts

(2) 3/8” - 16 x 3/4”

Truss head bolts

Clevis pins

(as required)

5/16” x 2” tamper-resistant Hex Head Lag

1/4” - 14 x 7/8” Self drilling

(2) 1/4”- 20 X 5/8” Tamper

Screws (as required)

screws (as required)

resistant screws

Stud plates

(as required)

Door Height Bottom Lock (second) Intermediate (third) Intermediate II (fourth) Top

6’0” 18” 18” 18” NA 18”

6’6” 21” 18” 18” NA 21”

18” Or 21”

7’0” 21” 21” 21” NA 21”

7’6” 18” 18” 18” 18” 18”

8’0” 21” 18” 18” 18” 21”

When installing your door you must use sections of the appropriate height in the right stacking order. What sections heights you need to use in what order depends on the height of your door.

WARNING LABEL

Unless your door is ﬁve sections in height, you will not receive an Intermediate II section.

The BOTTOM SECTION can be identiﬁed by the factory attached bottom

INTERMEDIATE I SECTION

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.

BOTTOM BRACKET

ASTRAGAL

WARNING LABELS

BOTTOM SECTION

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

Tools Required

Power drill

Phillips head screw-

driver

Sawhorse

Pencil

7/16”, 1/2” & 9/16”

Socket

Flat tip screwdriver

9/32”, 1/2”, 3/16” & 1/8” Drill

Ratchet wrench

bits

Removing An Old Door

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

PRE-INSTALLATIONPRE-INSTALLATION

Hammer

Step ladder

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

Tools Needed:

Recommended tools

from

page 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.

Header board 2” x 6” lumber recommended

Level header

Suitable mounting surface 2” x 6” lumber minimum

Door height

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.

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):

Plumb jambs

Door width

Headroom

Backroom

Header

Jamb

Weather seal

Jamb

Cut the weather seal if necessary to ﬁt the header and jambs.

For quick install track: Align the header seal with the inside edge of the header and temporarily secure it to the header with equally spaced nails. Next, ﬁt the jamb seals up tight against the header seal and ﬂush with the inside edge of the jamb. Temporarily secure the jamb seals with equally space nails. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.

For fully adjustable track: Align the header seal 1/8” to 1/4” inside the header and temporarily secure it to the header with equally spaced nails. Next, ﬁt the jamb seals up tight against the header seal and 1/8” to 1/4” inside the jamb. Temporarily secure the jamb seals with equally spaced nails. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.

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.

Jamb

Quick Install Track

TRACK TYPE

12” Radius Track 12 1/2”

15” Radius Track 14-1/2”

DOOR HEIGHT TRACK

6’0”, 7’0” 12”, 15” Radius 98” 125”

Weather

seal

Jamb

1/8” to 1/4”

Fully adjustable Track

HEADROOM REQUIREMENT

Torsion Springs

BACKROOM REQUIREMENT

MANUAL

LIFT

Weather

MOTOR

OPERATED

7’6”, 8’0” 12”, 15” Radius 110” 137”

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

seal

Installation

Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb and level with header. Side clearance, from edge of door to wall, must be a minimum of 3-1/2” (89mm) on each side.

IMPORTANT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, OPERATOR MOUNTING/SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT 2000 COATED LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.

NOTE: It is recommended that 5/16” lag screws be pilot drilled using a 3/16” drill bit, prior to fastening. NOTE: Use this manual in conjunction with the windload speciﬁcation sheet provided with your door.

Tools Needed:

None

Attaching Quick Install Flag

Angle to Vertical Track

NOTE: If you have fully adjustable ﬂagangles, skip

this step and complete Step 2.

Place the lower quick install tab of the ﬂagangle in the quick install feature of the vertical track. Give the ﬂagangle 1/4 turn to lock in place. Repeat for other side.

NOTE: After completing this step, continue with Step

Attaching Fully Adjustable

Flagangle to Vertical Track

Quick install tab unlocked

Flagangle

Vertical

track

Left hand track and ﬂagangle

Fully adjustable ﬂagangle

Quick install tab locked

Flagangle

INSTALLATION

Vertical

track

Right hand track and ﬂagangle

(2) 1/4”- 20 x 9/16” Track bolts

Tools Needed:

None

NOTE: If you have quick install ﬂagangles, skip this step and complete Step 3.

Attaching fully adjustable flagangle to universal vertical track:

Hand tighten the ﬂagangle to the vertical track using (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4”

- 20 ﬂange hex nuts. Repeat for other side.

Secure the ﬂange nuts after ﬂagangle spacing is complete (Step 16).

Attaching fully adjustable flagangle to quick install vertical track:

Hand tighten the ﬂagangle to the vertical track using (1) stud plate and (2) 1/4” - 20 ﬂange hex nuts. Repeat for other side.

Secure the ﬂange nuts after ﬂagangle spacing is complete (Step 16).

(2) 1/4”- 20 Flange hex nuts

(2) 1/4”- 20 Flange

hex nuts

Quick install vertical track

Universal vertical track

Fully adjustable ﬂagangle

Stud plate

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Horizontal Angle

Tabs

Horizontal angle

Tools Needed:

Hammer

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.

NOTE: For larger doors, a full length horizontal angle may be spot welded to the horizontal track. If the horizontal angle is not welded, the horizontal angle will be installed as shown.

Hole

Horizontal angle

Horizontal track

Hole

Horizontal track

Key slots

Horizontal

angle

Key slots

Horizontal track

Tabs

Horizontal track

(JB-US) JAMB BRACKET SCHEDULE

Tools Needed: Tape Measure

Installing JB-US Jamb Brackets

NOTE: The following (JB-US) denotes a slotted jamb

bracket.

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.

Loosely fasten the (JB-US) jamb bracket to the track with a 1/4”-20 x 9/16” track bolt and nut.

Vertical track

(JB-US) Jamb bracket

(1) 1/4” -

20 X 9/16”

Track bolt

(1) 1/4”- 20 Flange hex nut

(JB-US) JAMB BRACKET INSTALLATION

DOOR HEIGHT

NO. OF SECTIONS

WINDLOAD SPECIFICATION 1101, 1102, 1120, 1121, 1122, 1140, 1141, 1143

6’-0” 4 1 33 1/2” (JB-US)

6’-6’’ 4 2 34” (JB-US), 56” (JB-US)

7’-0’’ 4 2 29 1/2” (JB-US), 63 1/4” (JB-US)

7’-6’’ 5 1 28 1/2” (JB-US)

8’-0’’ 5 2 34” (JB-US), 58” (JB-US)

6’-0” 4 2 2” (JB-US), 23” (JB-US), 33 1/2” (JB-US)

6’-6’’ 4 3 2” (JB-US), 23 1/2” (JB-US), 34” (JB-US), 56” (JB-US)

7’-0’’ 4 4 2” (JB-US), 25 1/2” (JB-US), 34” (JB-US), 63 1/4”

7’-6’’ 5 4 2” (JB-US), 24 1/2” (JB-US), 32 1/2” (JB-US), 49”

8’-0’’ 5 5 2” (JB-US), 23” (JB-US), 34” (JB-US), 58” (JB-US), 75

6’-6’’ 4 7 2” (JB-US), 10” (JB-US), 21 3/4” (JB-US), 29 3/4” (JB-

7’-0’’ 4 7 2” (JB-US), 10” (JB-US), 21 3/4” (JB-US), 29 3/4” (JB-

7’-6’’ 5 8 2” (JB-US), 10” (JB-US), 18 3/4” (JB-US), 26 3/4”

8’-0’’ 5 8 2” (JB-US), 10” (JB-US), 21 3/4” (JB-US), 29 3/4”

NO. OF JAMB BRACKETS (EACH JAMB)

WINDLOAD SPECIFICATION 1123

WINDLOAD SPECIFICATION 1103, 1104, 1124, 1125, 1142, 1144

LOCATION OF CENTER LINE OF JAMB BRACKETS MEASURED FROM BOTTOM OF TRACK (ALL DIMENSIONS ± 2”)

(JB-US)

1/2” (JB-US)

US), 39” (JB-US), 48” (JB-US), 57 1/4” (JB-US)

US), 42” (JB-US), 52 1/2” (JB-US), 63 1/4” (JB-US)

(JB-US), 36” (JB-US), 45” (JB-US), 54 1/4” (JB-US), 74 1/2” (JB-US)

(JB-US), 39” (JB-US), 48” (JB-US), 57 1/2” (JB-US), 75 1/2” (JB-US)

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

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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.) jamb bracket with the quick install feature in the track and turn the jamb bracket perpendicular to the track so the mounting ﬂange is toward the back leg of the track.

Q.I. JAMB BRACKET SCHEDULE

WINDLOAD SPECIFICATION 1100, 1101, 1102, 1120, 1121, 1122, 1123, 1140, 1141, 1143

DOOR

HEIGHT

6’0”

(4 SECTIONS)

6’6”

(4 SECTIONS)

7’0”

(4 SECTIONS)

7’6”

(5 SECTIONS)

1ST SET 2ND SET 3RD SET

JAMB BKT POSITION JAMB BKT POSITION JAMB BKT POSITION

QIJB - 9 Middle QIJB - 11 Middle Not applicable

QIJB - 9 Middle QIJB - 10 Bottom Not applicable

QIJB - 9 Top QIJB - 10 Middle QIJB - 11 Middle

Tools Needed:

Power Drill

7/16” Socket Driver

1/4” Torx bit

Needle Nose Pliers

Twist lock

tabs

Q.I. jamb bracket

Q.I. JAMB BRACKET

Top hole

Middle hole

Bottom hole

QUICK INSTALL

FEATURE

Bottom Bracket

NOTE: For door section identiﬁcation see page 4. IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS

DETERMINED FROM INSIDE THE GARAGE LOOKING OUT.

Refer to the u-bar schedule to determine if the bottom section requires a u-bar. If the bottom section requires a u-bar, position the u-bar over the bottom brackets and center the u-bar side to side on the bottom section.

NOTE: Refer to illustrations (A) or (B) to determine which bottom bracket was supplied with your door. Follow the corresponding step below:

BOTTOM BRACKET (A): Align the center hole of left hand bottom bracket with hole #3 in the end stile of the bottom section. Attach the left hand bottom bracket with (1) 1/4”-14 x 5/8” self tamper-resistant drilling screw. Position a u-bar (if applicable) over the bottom brackets and center the u-bar side to side on the bottom section. Secure the u-bar / bottom bracket into the endstile using (2) 1/4”-14 x 7/8” self drilling screws. Repeat for the right hand side. Now, ﬁnish securing the u-bar to the section using (2) 1/4”-14 x 7/8” self drilling screws at each center stile location.

BOTTOM BRACKET (B): Uncoil the counterbalance cables and secure the cable loop to the clevis pin and bottom bracket using a 5/16” ﬂat washer and cotter pin. Repeat for other bottom bracket.

8’0”

(5 SECTIONS)

LEFT SIDE SHOWN

Door Height Section

6’- 0” to 8’- 0” Bottom Bottom X

END STILE HOLE

PATTERN (LEFT SIDE

IS SHOWN. RIGHT

SIDE IS OPPOSITE.)

QIJB - 9 Top QIJB - 10 Middle QIJB - 11 Middle

RIGHT SIDE SHOWN

(Q.I.) JAMB BRACKET INSTALLATION

U-Bar Schedule

Position of

u-bar on

section

End stile

1 2

Warning

label

#3 Hole

Bottom bracket

(1) 1/4”- 14 x 5/8”

Self drilling tamper-

resistant screw

Windload Option Codes: 1104 / 1123 /

1124 / 1125 /1142 / 1143 / 1144

Bottom section

(A)

Left hand

bottom

2 1

bracket

Clevis

(B)

U-bar

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

Counterbalance

cable

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

INSTALLATION

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