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Installation Instruction And Owenrs Manual
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Wayne-Dalton 8300, 8500 User Manual 2

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Page 1
8300/8500
t o r S i o n
Standard Lift and
L i g h t C o m m e r C i a L
mh
inStaLLation inStruCtionS and owner’S manuaL
T a b l e O f C o n t e n t s
Pre-Installation 2
Important Safety Instructions 2 Tools Required 2 Package Contents 2 Door Section Identification 3 Removing an Existing Door 4 Preparing the Opening 4
Parts Breakdown 6 Installation 7 Optional Installation 21
Trolley Arm Hookup 21 Inside Lock 21 Pull Down Rope 21
Maintenance 22
Cleaning Your Garage Door 22 Painting Your Garage Door 22 Operation And Maintenance 22
Warranty 24
PLEASE DO NOT RETURN THIS PRODUCT
TO THE STORE
Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.
©Copyright 2013
Wayne-Dalton, a Division Of Overhead Door Corporation
IMPORTANT NOTICES!
Wayne-Dalton highly recommends that you read and fully understand the Installation Instructions and Owner’s Manual before you attempt this installation.
DEFINITION OF DOOR HEIGHTS:
1. Door Heights less than or equal to 8’0” (< = 8’0”) are considered Standard Lift Applications.
2. Door Heights greater than 8’0” (> 8’0”) are considered Light Commercial Applications.
The complete Installation Instructions and Owner’s Manual are available at no charge from:
Wayne-Dalton, a Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, Or Online At www.Wayne-Dalton.com
Part Number NEW 02/18/2013
351653
Page 2
Pre-Installation
Important Safety Instructions
IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT
DEFINITION OF KEY WORDS USED IN THIS MANUAL:
WARNINGWARNING
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.
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.
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 over 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, fasteners, counterbalance lift 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 instruc-
tions.
16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks.
Track systems are not intended or designed to support extra weight.
17. This door may not meet the building code wind load requirements in your area. For
your safety, you will need to check with your local building official for wind load code requirements and building permit information.
After installation is complete, fasten this manual near the garage door. IMPORTANT: STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN
INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, DRAWBAR OPERATOR MOUNTING/ SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT2000 LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.
NOTE: It is recommended that 5/16” lag screws are pilot drilled using a 3/16” drill bit, prior to fastening.
IMPORTANT: WHEN INSTALLING 5/16” LAG SCREWS USING AN ELECTRIC DRILL/ DRIVER, THE DRILL/ DRIVERS CLUTCH MUST BE SET TO DELIVER NO MORE THAN 200 IN-LBS OF TORQUE. FASTENER FAILURE COULD OCCUR AT HIGHER SETTINGS.
Tools Required
• Power drill
• Drill bits: 1/8”, 3/16”, 9/32”, 7/16”, 1/2”
• Ratchet wrench
• Socket driver: 7/16”
• Sockets: 7/16”, 1/2”, 9/16”, 5/8”
• Phillips head screwdriver
• Locking Pliers
• (2) Vice clamps
• Wrenches: 3/8”, 7/16”, 1/2”, 9/16”, 5/8”
• 1/4” Torx bit
• Approved winding rods
• Hammer
• Tape measure
• Step Ladder
• Level
• Pencil
• Leather gloves
• Safety glasses
Package Contents
NOTE: Depending on the door model, some parts listed will not be supplied if not required. Rear Back Hangs may not be included with your door.
Door sections (as required)
Torsion shaft / Torsion keyed shaft (as required)
Torsion keyed shafts (as required)
Q.I. flag angles RH/LH (as required)
(2) Horizontal angles (as required)
Q.I. jamb brackets
(as required)
Pull down rope
(if included)
F.A. jamb brackets
(2) Spacers
(as required)
Angle mount vertical track assemblies RH/LH (as required)
Riveted vertical track assemblies RH/LH (as required)
(as required)
Track rollers
(as required)
F.A. flag angles RH/LH (as required)
Vertical tracks RH/LH (as required)
Horizontal tracks RH/LH (as required)
Weather seals & nails
(If included)
2” Strut (U-shaped)
(if included)
Drawbar operator
bracket (if included)
3” Strut (U-shaped)
(if included)
WARNINGWARNING
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.
Top fixture assemblies
(as required)
Top fixture base
(as required)
Top fixturue slide
(as required)
Graduated hinges
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Bottom corner brackets
RH/LH (as required)
Bottom corner brackets
RH/LH (as required)
Bottom corner brackets
RH/LH (as required)
3/8” Washers
(as required)
5/16” x 1 5/8” Hex head lag screws
(as required)
(2) Lift handles
& spacers
Counterbalance lift cables
Cable drums RH/LH
(as required)
drilling screws (as required)
1/4”-20 x 9/16”
Track bolts (as required)
3/8”- 16 Hex nuts
(as required)
(1) Step plate
Keys
1/4”-20 x 5/8” Self
hex nuts (as required)
3/8” - 16 x 1-1/2” Hex head bolts
(1) Step plate
(Inside)
Torsion springs RH/LH
assembly (as required)
Carriage bolts (as required)
5/16”-18 Flange
(Outside)
Center bracket (as required)
Center coupler
1/4”-20 x 7/8” Self
drilling screws (as required)
5/16”-18 x 3/4”
hex nuts (as required)
(as required)
Strut clips
(as required)
End bearing bracket RH/LH (as required)
1/4”-20 x 11/16” Self
drilling screws (as required)
drilling screws (as required)
5/16”-18 Hex
nuts (as required)
1/4”- 20 Flanged
Stud Plate
(as required)
Center bracket
bushing (as required)
1/4”-14 x 5/8”
Tamper resistant Self
1/4” - 20 Hex
nuts (lift handles)
5/16”-18 x 1/2”
Carriage
bolts (as required)
(2) 3/8”-16 x 3/4”
Truss head bolts
Cotter ring
(as required)
Clevis pin
(as required)
5/16” x 2” Tamper-resistant hex head
Cotter pin (as required)
lag screw (as required)
Clevis pin (as required)
5/16” x 1-1/4”
Door Section Identification
Type Of Sections
Section
Quantity
Door
Height
Bottom Lock
Int I Int II Int III Int IV Int V Int VI
3 6’0” 24” 24” N/A 24”
6’0” 18” 18” 18”
6’3” 21” 18” 18” 18”
6’6” 21” 18” 18” 21”
6’9” 21” 21” 18” 21”
7’0” 21” 21” 21” 21”
4
7’3” 24” 21” 21” 21”
7’3” 21” 21” 21” 24”
7’6” 24” 21” 21” 24”
7’9” 24” 24” 24” 21”
7’9” 24” 24” 21” 24”
8’0” 24” 24” 24” 24”
7’6” 18” 18” 18” 18”
7’9” 21” 18” 18” 18” 18”
8’0” 21” 18” 18” 18” 21”
8’3” 21” 21” 18” 18” 21”
8’6” 21” 21” 18” 21” 21”
8’9” 21” 21” 21” 21” 21”
5
9’0” 24” 21” 21” 21” 21”
9’0” 21” 21” 21” 21” 24”
9’3” 24” 21” 21” 21” 24”
9’6” 24” 24” 21” 21” 24”
9’9” 24” 24” 21” 24” 24”
10’0” 24” 24” 24” 24” 24”
Intermediate(s) Section
N/A
N/A
Top
18”
18”
5/16” x 1-5/8” Tamper-resistant hex head lag screws (as required)
#8 x 1” Pan head screws
(as required)
1/4” - 20 x 2-1/2” Carriage bolts (as required)
Self tapping screws (step plate)
(2) #8 x 1-5/8”
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Type Of Sections
Section
Quantity
6
7
8
9
Door
Height
Bottom Lock
Int I Int II Int III Int IV Int V Int VI
9’0” 18” 18” 18” 18” 18”
9’3” 21” 18” 18” 18” 18” 18”
9’6” 21” 18” 18” 18” 18” 21”
9’9” 21” 21” 18” 18” 18” 21”
10’0” 21” 21” 18” 18” 21” 21”
10’2” 21” 21” 21” 18” 21” 21”
10’5” 21” 21” 21” 21” 21” 21”
10’8” 21” 21” 21” 21” 21” 24”
11’0” 24” 21” 21” 21” 21” 24”
11’3” 24” 24” 21” 21” 21” 24”
11’6” 24” 24” 21” 21” 24” 24”
11’9” 24” 24” 24” 21” 24” 24”
12’0” 24” 24” 24” 24” 24” 24”
10’6” 18” 18” 18” 18” 18” 18”
10’9” 21” 18” 18” 18” 18” 18” 18”
11’0” 21” 18” 18” 18” 18” 18” 21”
11’3” 21” 21” 18” 18” 18” 18” 21”
11’6” 21” 21” 18” 18” 18” 21” 21”
11’8” 21” 21” 21” 18” 18” 21” 21”
11’11” 21” 21” 21” 18” 21” 21” 21”
12’2” 21” 21” 21” 21” 21” 21” 21”
12’5” 21” 21” 21” 21” 21” 21” 24”
12’8” 24” 21” 21” 21” 21” 21” 24”
13’0” 24” 24” 21” 21” 21” 21” 24”
13’3” 24” 24” 21” 21” 21” 24” 24”
13’6” 24” 24” 24” 21” 21” 24” 24”
13’9” 24” 24” 24” 21” 24” 24” 24”
14’0” 24” 24” 24” 24” 24” 24” 24”
12’0” 18” 18” 18” 18” 18” 18” 18”
12’3” 21” 18” 18” 18” 18” 18” 18” 18”
12’6” 21” 18” 18” 18” 18” 18” 18” 21”
12’9” 21” 21” 18” 18” 18” 18” 18” 21”
13’0” 21” 21” 18” 18” 18” 18” 21” 21”
13’2” 21” 21” 21” 18” 18” 18” 21” 21”
13’5” 21” 21” 21” 18” 18” 21” 21” 21”
13’8” 21” 21” 21” 21” 18” 21” 21” 21”
13’11” 21” 21” 21” 21” 21” 21” 21” 21”
13’6” 18” 18” 18” 18” 18” 18” 18” 18” 18”
13’9” 21” 18” 18” 18” 18” 18” 18” 18” 18”
14’0” 21” 18” 18” 18” 18” 18” 18” 18” 21”
Intermediate(s) Section
Top
18”
N/A
18”
N/A
18”
N/A
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.
Unless your door is six sections in height, you will not receive an Intermediate III section. The BOTTOM SECTION can be identified by the factory attached bottom astragal and 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 end stile of the section. This section is always the 3rd section from the bottom of the door.
Warning labels
Intermediate I section
Section
height
Bottom corner bracket warning labels
Bottom weather seal
Bottom section
Section side view
Removing an Existing Door
IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.
WARNINGWARNING
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 not supplied with the door, but are available at no charge from Wayne-Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at www.Wayne-Dalton.com.
Preparing the Opening
IMPORTANT: 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 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 12” (305 mm) above the top of the opening for Torsion counterbalance systems. 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 JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE REPLACED.
For Torsion counterbalance systems, a suitable mounting surface (2” x 6”) must be firmly attached to the wall, above the header at the center of the opening.
NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting the lumber. Do not attach the mounting surface with nails.
WEATHERSTRIPS (MAY NOT BE INCLUDED):
Depending on the size of your door, you may have to cut or trim the weatherstrips (if neces­sary) to properly fit into the header and jambs.
NOTE: If nailing product at 40°F or below, pre-drilling is required. NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.
For Quick Install track: For the header, align the weatherstrip with the inside edge of the header and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and flush with the inside edge of the jamb. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.
For other tracks: For the header, align the weatherstrip 1/8” to 1/4” inside the header edge, and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and 1/8” to 1/4” inside the jamb edge. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.
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.
NOTE: 6” low headroom conversion kit is available for 12” radius only. Contact your local
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Wayne-Dalton dealer. 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.
BACKROOM REQUIREMENTS
Door Height Track Manual Lift Motor Operated
6’0” to 7’0”
7’1” to 8’0” 114-1/2” (2909 mm) 137” (3480 mm)
8’1” to 9’0” 127” (3226 mm) 168” (4267 mm)
9’1” to 10’0” 139” (3531 mm) 168” (4267 mm)
10’1” to 12’0” 163-1/2” (4153 mm) See *NOTE
12’1” to 14’0” 187-1/2” (4763 mm) See *NOTE
12”, 15” Radius
102-1/2” (2604 mm) 125” (3175 mm)
HEADROOM REQUIREMENTS
Track Type Space Needed
12” Radius 12-1/2” (318 mm)
15” Radius 14-1/2” (368 mm)
Min. Side
Suitable mounting surface 2”x 6” lumber minimum
Header board 2”x 6” lumber preferred
Headroom
room Clearance is 3 1/2”
Backroom
Min. Side room Clearance is 3 1/2”
Weatherstrips
Plumb jambs
Finished
Jambs
Level header
Finished
Height
Door width
Door
Quick Install track
Other track systems
Jamb
Jamb
Nail
1/8” to 1/4”
Weather­strips
Weather­strips
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J3.
PARTS BREAKDOWN
NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations.
J6.
J6.
J5.
J5.
J8.
J3.
J4.
J3.
A2.
A1.
J2.
D1.
B2.
B1.
I3.
I4.
C1.
I2.
L1.
C1.
J8.
J5.
J7.
J6.
J5.
J1.
F3.
F1.
F2.
D2.
C2.
A. FLAG ANGLES (AS REQUIRED):
A1. Quick Install (Q.I.) Flag Angles A2. Fully Adjustable (F.A.) Flag Angles
B. JAMB BRACKETS (AS REQUIRED):
B1. Quick Install (Q.I.) Jamb Brackets B2. Fully Adjustable (F.A.) Jamb Brackets
C. TRACK ROLLERS (AS REQUIRED):
C1. Short Stem Track Rollers C2. Long Stem Track Rollers
D. GRADUATED END HINGES:
D1. Single Graduated End Hinges (S.E.H.), Industry Standard D2. Double Graduated End Hinges (D.E.H.), Industry Standard
E. STACKED SECTIONS:
E1. Top Section E2. Intermediate(s) Section E3. Lock Section E4. Bottom Section
F. TOP FIXTURE (AS REQUIRED):
F1. Top Fixture Bases - (L-Shaped) F2. Top Fixture Slides - (L-Shaped) F3. Top Fixture Assemblies
G. STRUT(S) (AS REQUIRED):
G1. 2” Strut (U-shaped) G2. 3” Strut (U-shaped)
J8.
J3.
J8.
J7.
J9.
J6.
J1.
J7.
K1.
J2.
J4.
F1.
F2.
F3.
E1.
E2.
E3.
E4.
L1.
I1.
C1.
A2.
I1.
A1.
B1.
B2.
I2.
G1.
I3.
I4.
G2.
Top of vertical track
3rd hole set
2nd hole set
1st hole set
H2.
H1.
B1. (Quick
Install
Feature)
Top
hole
Middle
hole
Bottom
hole
K1.
Top of vertical track
3rd hole set
2nd hole set
1st hole set
B2. (Fully
Adjustable
Feature)
Lower hole of hole/ slot pattern
H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):
H1. Top Halve Drawbar Operator Bracket H2. Bottom Halve Drawbar Operator Bracket H3. Drawbar Operator Bracket (Supplied By Others)
I. TRACKS (AS REQUIRED):
I1. Left Hand and Right Hand Horizontal Track Assemblies I2. Left Hand and Right Hand Vertical Tracks I3. Left Hand and Right Hand Riveted Vertical Track Assemblies I4. Left Hand and Right Hand Angle Mount Vertical Track Assemblies
J. TORSION SPRING ASSEMBLY (AS REQUIRED):
J1. Left Hand and Right Hand Torsion Springs (As Required) J2. Counterbalance Lift Cables J3. Left Hand and Right Hand End Bearing Brackets (As Required) J4. Left Hand and Right Hand Cable Drums J5. Center Bushing / Center Bearing (As Required) J6. Center Bracket(s) (As Required) J7. Torsion Shaft / Torsion Keyed Shaft / Torsion Keyed Shafts (As Required) J8. Keys (As Required) J9. Center Coupler Assembly (As Required)
K. REAR BACK HANGS:
K1. Left Hand and Right Hand Rear Back Hang Assemblies
L. BOTTOM CORNER BRACKETS (AS REQUIRED):
L1. Left Hand and Right Hand Bottom Corner Brackets
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INSTALLATION
Quick Install tabs
Horizontal track angle
Before installing your door, be certain that you have read and followed all of the instruc­tions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door.
NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.
Quick Install Flag Angles
1
NOTE: If you have Fully Adjustable Flag Angles, Riveted Track or Angle Mount Track, skip this step.
NOTE: Flag angles are right and left handed. Place the lower Quick Install tab of the left hand flag angle in the Quick Install feature of the
left hand vertical track. Give the flag angle 1/4 turn to lock in place. Repeat for other side.
Tools Required: None
Flag angle
Vertical track
Lower Quick Install tab
Quick Install feature
1/4 Turn
Fully Adjustable Flag Angles
2
Tools Required: None
Alignment hole
Quick
Install tabs
Horizontal
Horizontal track
Horizontal track
angle
track
Key slots
Key slots
Horizontal
Quick
Install tabs
track
Quick Install tabs in place
Horizontal track
angle
Quick Install tabs
in place
Quick Install Jamb Brackets
1st hole set
Tools Required: None
Vertical track
2nd hole set 3rd hole set
Top of track
4
NOTE: If you have Fully Adjustable Flag Angles, Riveted Track or Angle Mount Track, skip this step.
Measure the length of the vertical tracks. Using the jamb bracket schedule, determine the placement of the jamb brackets for your door height and track length. To install the jamb brackets, align the Quick Install tab on the Quick Install jamb bracket with the Quick Install feature in the vertical track and turn the bracket perpendicular to the track so the mounting flange is toward the back (flat) leg of the track. Repeat for other side.
NOTE: If you have Quick Install flag angles, Riveted Track or Angle Mount Track, skip this step.
NOTE: Flag angles are right and left handed. If you have Quick Install vertical tracks, hand tighten the left hand flag angle to the left hand
vertical track using (1) stud plate and (2) 1/4” - 20 flange hex nuts. Repeat for the other side. If you have Fully Adjustable vertical tracks, hand tighten the left hand flag angle to the left
hand vertical track using (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 flange hex nuts. Repeat for other side. Flange nuts will be secured after flag angle spacing is completed in step, Top Section.
Flag angle
1/4”-20 Flange hex nuts
Quick Install vertical track
Stud plate
Flag angle
1/4”-20 Flange hex nuts
Fully Adjustable vertical track
1/4”- 20 x 9/16” Track bolts
Horizontal Track Angles
3
NOTE: For larger doors, a full length horizontal track angle may not already be spot welded to the horizontal track. If the horizontal track angle is not welded, the horizontal track angle will be installed, as shown.
Position the left hand horizontal track angle, as shown. Place the Quick Install tabs of the horizontal track angle in the key slot of the left hand horizontal track. Using a hammer, tap the horizontal track angle towards the curved end of the track until the alignment hole in the track and angle are aligned. Repeat for other side. Set tracks aside.
Tools Required: Hammer
Bottom hole Middle hole Top hole
Q.I. tab
DOOR HEIGHT
6’0”
6’3”
6’6”
6’9”
7’0”
7’6”
7’9”
8’0”
5
Jamb bracket in place
Q.I. jamb
bracket
JAMB BRACKET SCHEDULE
TRACK
LENGTH
64” (1626
mm)
67” (1702
mm)
70” (1778
mm)
73” (1854
mm)
76” (1930
mm)
82” (2083
mm)
85” (2159
mm)
88”
(2235mm)
1ST SET 2ND SET 3RD SET
9 M 11 M NA
9 B 11 M NA
9 M 10 B NA
9 M 10 B NA
9 M 10 B NA
9 T 10 M 11 M
9 T 10 M 11 M
9 T 10 M 11 M
B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE
Mounting flange
Fully Adjustable Jamb Brackets
Tools Required: None
NOTE: If you have Quick Install jamb brackets, Riveted Track or Angle Mount Track, skip this step.
7
Page 8
NOTE: The bottom jamb bracket is always the shortest bracket, while the center jamb bracket is the next tallest. If three jamb brackets per side are included with your door, you will have received a top jamb bracket, which is the tallest.
To attach the bottom jamb bracket, locate lower hole of the hole/ slot pattern of the 1st hole set on the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/ slot pattern. Secure jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.
Place the center jamb bracket over the lower hole of the hole/ slot pattern that is centered between the bottom jamb bracket and flag angle of the 2nd hole set. Secure jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.
If a top jamb bracket was included, secure it to vertical track using the lower hole of the hole/ slot pattern in the 3rd hole set and (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.
1st hole set
Vertical track
2nd hole set 3rd hole set
Top of track
Counterbalance
lift cable
End cap
Counterbalance
cable loop
Cotter pin (attached into place from opposite side of bottom bracket)
Clevis pin (inserted through
cotter pin and bent into place)
Washer
Short stem track roller
Roller spacer
Bottom corner bracket
Bottom section
Bottom weather
seal
(4) 1/4”-20 x 11/16” Self drilling screws
1/4”-14 x 5/8” Tamper resistant self drilling screw
Lower hole of hole/ slot pattern
1/4”- 20 Flange hex nut
F.A. jamb
bracket
1/4”- 20 x 9/16” Track bolt
Jamb bracket in place
Bottom Corner Brackets
6
NOTE: Refer to Package Contents / Parts Breakdown, to determine which bottom corner brackets you have.
Uncoil the counterbalance lift cables. Depending on which bottom corner brackets you have (reference illustrations below), slip the loop at the ends of the counterbalance lift cable over the milford pin of the bottom corner bracket or secure the cable loop to the clevis pin and bottom corner bracket using a flat washer and a cotter pin. Repeat for other bottom corner bracket.
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Saw horses
WARNINGWARNING
FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN, ALLOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR FATAL INJURY.
Starting on the left hand side, attach the left hand bottom corner bracket to the left corner of the bottom section, making sure it is seated to the edges of the end cap, using 1/4” - 20 x 11/16” self drilling screws, roller spacer (if applicable) washer (if applicable) and (1) 1/4” ­14 x 5/8” tamper resistant self drilling screw. Repeat for right hand bottom corner bracket.
NOTE: All doors are provided with the tamper resistant fastener for the bottom corner 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” - 20 x 11/16” self drilling screw in its place.
NOTE: Check to ensure cable loop fits tightly over the milford pins. Insert a short stem track roller with roller spacer into the bottom corner bracket. Repeat for
other side. NOTE: Verify bottom weather seal (bottom seal) is aligned with door section. If there is more
than 1/2” excess bottom weather seal on either side, trim bottom weather seal even with door section.
Counterbalance
Short stem track roller
Counterbalance
lift cable
End cap
cable loop
Milford pin
Roller spacer
Bottom corner bracket
Bottom weather
seal
Bottom section
(2) 1/4”-20 x 11/16” Self drilling screws
1/4”-14 x 5/8” Tamper resistant self drilling screw
Counterbalance
Counterbalance
Short stem track roller
End cap
lift cable
cable loop
Milford pin
Roller spacer
Bottom corner bracket
(4) 1/4”-20 x 11/16” Self drilling screws
Bottom section
Bottom weather
seal
1/4”-14 x 5/8” Tamper resistant self drilling screw
Graduated Hinge / Strut Attachment
7
NOTE: Refer to door section identification, located in the pre-installation section of this manual to determine what size sections you need to use as your lock (second) section, inter­mediate (third) section, intermediate (fourth) section, intermediate (fifth) section, intermediate (sixth) section, intermediate (seventh) section, intermediate (eighth) section and top section. Measure your sections to make sure they are the correct height as indicated on the chart.
NOTE: The graduated end hinges can be identified by the number stamped on the lower hinge leaf. The #1 graduated end hinges serves as end hinges on the bottom section. The #1 graduated end hinges also serves as center hinges on all sections, except for the top section.
NOTE: The #2 graduated end hinges serves as end hinges on the Lock section. NOTE: The #3 graduated end hinges serves as end hinges on the Intermediate I section. NOTE: The #4 graduated end hinges serves as end hinges on the Intermediate II section. NOTE: The #5 graduated end hinges serves as end hinges on the Intermediate III section. NOTE: The #6 graduated end hinges serves as end hinges on the Intermediate IV section. NOTE: The #7 graduated end hinges serves as end hinges on the Intermediate V section. NOTE: The #8 graduated end hinges serves as end hinges on the Intermediate VI section. NOTE: Refer to the strutting schedules below to determine the placement of strut(s) on your
door. Be sure to use the proper schedules for the type of door model and the size of your door.
IMPORTANT: WHEN REFERRING TO THE STRUTTING SCHEDULES, DETERMINE HOW MANY STRUTS YOUR DOOR NEEDS AND ON WHAT SECTIONS THEY ARE NEEDED TO BE INSTALLED. ALSO BE SURE TO USE THE CORRECT STRUTTING SCHEDULE FOR ALUMINUM DOORS OR STEEL DOORS DEPENDING ON THE MATERIAL YOUR DOOR IS MADE OF. ALSO USE THE CORRECT STRUTTING SCHEDULE FOR THE PROPER COLOR OF YOUR DOOR.
NOTE: Sections not noted in the strutting schedule, do not require a strut. All strut(s) are placed at the top of the section(s).
IW = Intermediate Section With Windows LS = Lock Section
Using sawhorses, lay sections together on a flat smooth surface. Ensure the appropriate
Tools Required: Power drill, 7/16” Socket driver, Saw horses, Tape Measure
Strutting Schedule Key:
TS = Top Section I1 = Intermediate Section #1
I6 = Intermediate Section #6 BS = Bottom Section
I5 = Intermediate Section #5 ES = Every Section gets a strut.
I4 = Intermediate Section #4 RS = Remaining Sections gets a strut.
I3 = Intermediate Section #3 2S = 2” Strut
I2 = Intermediate Section #2 3S = 3” Strut
8
Page 9
graduated end hinges, center hinge(s) and strut (if applicable) are on top of their correspond­ing sections.
INSTALLATION ON TOP SECTION: Place the strut on the top edge of the top section, as shown. Center the strut side to side on the section, as shown. Secure the graduated end and center hinges to the section using (2) 1/4” - 20 x 7/8” self drilling screws at each graduated end / center hinge locations.
INSTALLATION ON ALL SECTIONS (EXCEPT TOP SECTION): Starting on the left hand side of the bottom section, align the lower leafs of the #1 graduated end hinge over the holes at the top of the end caps located at the top of bottom section. Next, align the lower hinge leafs of the #1 center hinges with the dimples at the center location(s) located at the top of the section. If applicable, place the strut on top of the graduated end and center hinges.
For Graduated End And Center Hinge Installation Only: Secure the graduated end and center hinges to the section using (2) 1/4” - 20 x 11/16” self drilling screws at each graduated end / center hinge locations.
For Strut, Graduated End And Center Hinge Installation Only: Secure the strut to the gradu­ated end and center hinges to the section using (2) strut clips (if applicable) and (2) 1/4” - 20 x 7/8” self drilling screws at each graduated end / center hinge locations.
NOTE: If your Intermediate Section has windows in it and a strut needs to be installed on that section, strut clips will need to be used to attach it to the section.
IMPORTANT: ONCE THE 1/4” - 20 X 7/8” / 1/4” - 20 X 11/16” SELF DRILLING SCREWS ARE SNUG AGAINST THE LOWER HINGE LEAFS, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE MAXIMUM DESIGN HOLDING POWER.
Insert a short stem track roller into the hinge tube of the #1 graduated end hinges. Repeat graduated hinge / strut attachment using the appropriate graduated end hinges and strut (if applicable) for all remaining sections, except the top section.
NOTE: The top section only receives a strut (if applicable) and does not require graduated end hinges and center hinges to be installed onto the section.
IMPORTANT: WHEN PLACING SHORT STEM TRACK ROLLERS INTO THE #2 GRADUATED END HINGES AND HIGHER, THE SHORT STEM TRACK ROLLER GOES INTO HINGE TUBE FURTHEST AWAY FROM SECTION.
Strutting Schedule For Model 8300 Steel (White, Almond, and Taupe Colored Doors)
Door Heights
< = 8’0”
> 8’0”
12’0” - 14’0” 7-9
Door Heights
< = 8’0”
Section
Quantity
4 or 5
Strutting Schedule For Model 8300 Steel (Brown Colored Doors)
Section
Quantity
4
5
6
4
5
Door Con­figurations
Solid / Top (Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Solid
Top (Win-
dows)
Intermediate
(Windows)
Solid
Top (Win-
dows)
Intermediate
(Windows)
Solid
Top (Win-
dows)
Intermediate
(Windows)
Door Con-
figurations
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
10’0” -
14’0”
2S, TS
2S, TS /
2S, IW
2S, TS
2S, TS /
2S, IW
2S, TS
2S, TS /
2S, IW
2S, TS
2S, TS /
2S, IW
10’0”
2S, TS
2S, TS /
2S, IW
2S, TS 3S, TS / 3S, I1 / 3S, BS
2S, TS /
2S, IW
Door Widths
15’0” -
16’0”
2S, TS /
2S, LS
2S, TS /
2S, I1
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I1 / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I2 / 2S, BS
2S, TS / 2S, IW / 2S, BS
3S, TS / 2S,
I3 / 2S, I1 /
2S, BS
3S, TS / 2S, IW / 2S, I1 /
2S, BS
12’0” -
16’0”
2S, TS / 2S, LS / 2S, BS
2S, TS / 2S, IW / 2S, BS
3S, TS / 3S, IW / 3S, BS
17’0” -
18’0”
2S, TS / 2S, LS / 2S, BS
2S, TS / 2S,
I1 / 2S, BS
2S, ES
3S, TS /
2S, RS
2S, ES
2S, ES
3S, TS /
2S, RS
2S, ES
3S, TS / 2S,
I4 / 2S, I3 /
2S, I2 / 2S, I1
/ 2S, BS
Door Widths
17’0” -
18’0”
3S, TS / 3S, LS / 3S, BS
3S, TS / 3S, IW / 3S, BS
20’0”
3S, ES5
N/A
N/A
N/A
20’0”
3S, ES
3S, ES
Strutting Schedule For Model 8300 Steel (Brown Colored Doors)
Door Heights
> 8’0”
12’0” - 14’0” 7 - 9
Strutting Schedule For Model 8300 Aluminum (White, Almond & Taupe Colored Doors)
Door Heights
< = 8’0”
> 8’0”
Door Heights
< = 8’0”
Section
Quantity
Section
Quantity
4
5
5
6
Strutting Schedule For Model 8300 Aluminum (Brown Colored Doors)
Section
Quantity
5
6
4
5
Door Con-
figurations
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Door
Configura-
tions
Solid / Top (Windows)
Inter-
mediate
(Windows)
Solid
Top (Win-
dows)
Inter-
mediate
(Windows)
Solid
Top (Win-
dows)
Inter-
mediate
(Windows)
Solid
Top (Win-
dows)
Inter-
mediate
(Windows)
Door Con-
figurations
Solid / Top (Windows)
Intermediate
(Windows)
Solid
Top (Win-
dows)
Intermediate
(Windows)
2S, TS /
2S, TS /
2S, TS /
2S, TS /
6’0” - 9’0”
2S, TS
2S, TS
2S, TS
2S, TS
6’0” - 10’0”
10’0”
2S, TS
2S, IW
2S, TS
2S, IW
2S, I1
2S, IW
10’0” -
2S, TS /
2S, TS /
2S, TS /
2S, TS /
2S, TS
2S, TS
Door Widths
12’0” -
16’0”
3S, TS / 3S,
I1 / 3S, BS
3S, TS / 3S, IW / 3S, BS
3S, TS / 3S,
I2 / 3S, BS
3S, TS / 3S, IW / 3S, BS
3S, TS / 2S,
I3 / 2S, I1 / 2S, LS /
2S, BS
3S, TS / 2S,
IW / 2S, I1
/ 2S, LS /
2S, BS
Door Widths
15’0” -
14’0”
2S, TS
2S, IS
2S, TS
2S, IS
2S, TS
2S, IS
2S, TS
2S, IS
16’0”
2S, TS / 2S, LS / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I1 / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I2 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I1 /
2S, BS
2S, TS / 2S,
I2 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I1 /
2S, BS
Door Widths
12’0” -
16’0”
2S, TS / 2S, LS / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I1 / 2S, BS
2S, TS / 2S, IW / 2S, BS
17’0” -
18’0”
3S, ES N/A
3S, ES N/A
3S, ES N/A
17’0” -
18’0”
3S, TS / 3S,
LS / 3S, BS
3S, TS / 3S,
IW / 3S, BS
2S, TS / 2S,
I1 / 2S, BS
3S, TS / 2S,
I1 / 2S, BS
2S, ES
3S, TS /
2S, RS
2S, ES
2S, ES
3S, TS /
2S, RS
2S, ES
17’0” -
18’0”
2S, TS / 2S,
I1 / 2S, BS
3S, TS / 3S,
I1 / 3S, BS
3S, TS / 3S, IW / 3S, BS
20’0”
20’0”
3S, ES
3S, TS / 3S,
I2 / 3S, I1 /
3S, BS
3S, TS / 3S, IW / 3S, I1 /
3S, BS
N/A
N/A
20’0”
3S, ES
3S, ES
9
Page 10
Strutting Schedule For Model 8300 Aluminum (Brown Colored Doors)
Strutting Schedule For Model 8500 Steel (Brown Colored Doors)
Door Heights
> 8’0”
Strutting Schedule For Model 8500 Steel (White, Almond & Taupe Colored Doors)
Door Heights
< = 8’0”
> 8’0”
12’0” - 14’0” 7 - 9
Section
Quantity
Section
Quantity
4
5
5
6
5
6
Door Con-
figurations
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Door
Configura-
tions
Solid N/A
Top (Win-
dows)
Inter-
mediate
(Windows)
Solid N/A
Top (Win-
dows)
Inter-
mediate
(Windows)
Solid N/A
Top (Win-
dows)
Inter-
mediate
(Windows)
Solid N/A
Top (Win-
dows)
Inter-
mediate
(Windows)
Solid N/A
dows)
Inter-
mediate
(Windows)
6’0” - 10’0”
2S, TS
2S, TS
10’0”
2S, TS
N/A
2S, TS
N/A
2S, TS
N/A
2S, TS
N/A
2S, TS
N/A
12’0” -
2S, TS /
2S, TS /
2S, TS /
2S, TS /
2S, TS /
Door Widths
12’0” -
16’0”
3S, TS / 3S,
I2 / 3S, I1 /
3S, BS
3S, TS / 3S, IW / 3S, I1 /
3S, BS
3S, TS / 3S,
I2 / 3S, I1 /
3S, BS
3S, TS / 3S, IW / 3S, I1 /
3S, BS
Door Width
15’0” -
14’0”
2S, TS 2S, TS
2S, IW
2S, TS 2S, TS
2S, IW
2S, TS
2S, IW
2S, TS
2S, IW
2S, TS
2S, IW
16’0”
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS /
2S, I1
2S, TS / 2S, IW / 2S, BS
2S, TS /
2S, I2
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I3 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I1 /
2S, BS
17’0” -
18’0”
3S, ES N/A
3S, ES N/A
17’0” -
18’0”
2S, TS / 2S,
LS / 2S, BS
3S, TS / 2S,
LS / 2S, BS
2S, TS / 2S,
I1 / 2S, BS
3S, TS / 2S,
IW / 2S, BS
2S, TS / 2S,
I2 / 2S, I1 /
2S, BS
3S, TS / 2S,
I2 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I1 /
2S, BS
2S, TS / 2S,
I2 / 2S, I1 /
2S, BS
3S, TS / 2S,
I2 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I1 /
2S, BS
3S, TS / 2S,
I4 / 2S, I3
/ 2S, I1 /
2S, BS
3S, TS / 2S,
IW / 2S, I3
/ 2S, I1 /
2S, BS
20’0”
20’0”
3S, ES
3S, ES
N/A
N/A
N/ATop (Win-
Door Heights
< = 8’0”
> 8’0”
12’0” - 14’0” 7 - 9
Strutting Schedule For Model 8500 Aluminum (White, Almond & Taupe Colored Doors)
Door
Heights
< = 8’0”
Section
Quantity
Section
Quantity
4
5
4
5
5
6
Configu-
rations
Top (Win-
mediate
(Windows)
Top (Win-
mediate
(Windows)
Door
Solid
dows)
Inter-
Solid
dows)
Inter-
Door Con-
figurations
Solid / Top (Windows)
Intermediate
(Windows)
Solid
Top (Win-
dows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
6’0” -
9’0”
2S, TS 2S, TS
10’0”
2S, TS
2S, TS
2S, TS
2S, TS
2S, TS /
2S, IW
2S, TS
2S, TS /
2S, IW
10’0”
2S, TS
Door Widths
12’0” -
16’0”
2S, TS / 2S, LS / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S, LS / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S, I2 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I1 /
2S, BS
2S, TS / 2S, I2 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I1 /
2S, BS
2S, TS / 2S,
I4 / 2S, I2
/ 2S, I1 /
2S, BS
2S, TS / 2S,
IW / 2S, I2
/ 2S, I1 /
2S, BS
Door Widths
12’0” -
14’0”
2S, TS /
2S, LS
2S, TS /
2S, IW
2S, TS /
2S, I1
2S, TS /
2S, IW
17’0” -
18’0”
3S, TS / 3S, LS / 3S, BS
3S, TS / 3S, IW / 3S, BS
3S, TS / 3S, LS / 3S, BS
3S, TS / 3S, IW / 3S, BS
3S, TS / 3S,
I2 / 3S, I1 /
3S, BS
3S, TS / 3S,
IW / 3S, I1 /
3S, BS
3S, TS / 3S,
I2 / 3S, I1 /
3S, BS
3S, TS / 3S,
IW / 3S, I1 /
3S, BS
3S, TS / 3S,
I4 / 3S, I2
/ 3S, I1 /
3S, BS
3S, TS / 3S,
IW / 3S, I2
/ 3S, I1 /
3S, BS
15’0” -
17’0” -
16’0”
2S, TS / 2S, LS /
2S, TS / 2S, LS /
2S, TS /
2S, BS
3S, TS /
2S, BS
2S, LS /
2S, BS
2S, TS / 2S, IW /
2S, BS
2S, TS / 2S, I1 /
2S, BS
3S, TS /
2S, I1 /
2S, LS /
2S, BS
2S, BS
2S, TS / 2S, I1 /
2S, BS
18’0”
20’0”
3S, ES
3S, ES
N/A
N/A
N/A
20’0”
3S, ES
3S, TS /
3S, I2 / 3S, I1 /
3S, BS
3S, TS / 3S, IW /
3S, I1 /
3S, BS
10
Page 11
Strutting Schedule For Model 8500 Aluminum (White, Almond & Taupe Colored Doors)
Door
Heights
> 8’0”
Door Heights
< = 8’0”
> 8’0”
Section
Quantity
Strutting Schedule For Model 8500 Aluminum (Brown Colored Doors)
Short stem track roller
#1 Graduated
end hinge
Lower
hinge leaf
1/4”-20 x 7/8” Self drilling
Door
Configu-
rations
Solid 2S, TS
Top (Win-
5
dows)
Inter-
mediate
(Windows)
Solid 2S, TS
Top (Win-
6
dows)
Inter-
mediate
(Windows)
Section
Quantity
4
5
5
6
screw locations
6’0” -
9’0”
2S, TS
2S, TS
Door Con-
figurations
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
Solid / Top (Windows)
Intermediate
(Windows)
#1Center hinge(s)
10’0”
2S, TS /
2S, I1
2S, TS
2S, TS /
2S, I2
2S, TS
6’0” - 10’0”
2S, TS
2S, TS
2S, TS
2S, TS
Door Widths
12’0” -
15’0” -
14’0”
16’0”
2S, TS / 2S, I2 / 2S,
2S, TS /
2S, TS /
2S, I1
2S, I2 / 2S, I1 /
2S, BS
2S, TS /
2S, TS / 2S, IW / 2S,
2S, IW
2S, TS /
2S, TS /
2S, I2 /
2S, I2
2S, I1 /
2S, BS
2S, TS /
2S, TS /
2S, IW /
2S, IW
2S, I1 /
2S, BS
Door Widths
12’0” -
16’0”
2S, TS / 2S, LS / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I1 / 2S, BS
2S, TS / 2S, IW / 2S, BS
2S, TS / 2S,
I2 / 2S, I1 /
2S, BS
2S, TS / 2S,
IW / 2S, I1 /
2S, BS
2S, TS / 2S,
I2 / 2S, I1 /
2S, BS
2S, TS / 2S,
IW / 2S, I1 /
2S, BS
#2 Graduated end hinge
(short stem track roller
inserted into tube
furthest from section)
#1 Center hinge(s)
17’0” -
18’0”
I1 / 2S, BS
3S, TS / 2S, I2 / 2S, I1 /
2S, BS
I1 / 2S, BS
2S, TS / 2S, I3 / 2S, I2 / 2S, I1 /
2S, BS
3S, TS / 2S, I3 / 2S, I2 / 2S, I1 /
2S, BS
2S, TS / 2S, IW / 2S, I2 / 2S, I1 /
2S, BS
17’0” -
18’0”
3S, TS / 3S, LS / 3S, BS
3S, TS / 3S, IW / 3S, BS
3S, TS / 3S,
I1 / 3S, BS
3S, TS / 3S, IW / 3S, BS
3S, TS / 3S,
I2 / 3S, I1 /
3S, BS
3S, TS / 3S, IW / 3S, I1 /
3S, BS
3S, TS / 3S,
I3 / 3S, I2
/ 3S, I1 /
3S, BS
3S, TS / 3S,
IW / 3S, I2
/ 3S, I1 /
3S, BS
End stile
20’0”
N/A
N/A
20’0”
3S, ES
3S, ES
N/A
N/A
Strut
(2) 1/4”-20 x 7/8” Self drilling screws
Strut installation at top of section
Graduated end hinge
(2) Strut clips
Center hinge
Strut
(2) 1/4”-20 x 7/8”
Self drilling screws
Strut installation across Graduated end hinge and center hinges
(2) Strut clips
Strut
(2) 1/4”-20 x 7/8” Self drilling screws
Step Plate
8
Locate the center most center stile on the bottom section of the door. On the inside of the door and using the pre-punched holes at the bottom of the center stile as a template, drill (2) 7/32” dia. holes through the section. Using the previously drilled holes as a guide, enlarge the holes from outside the door to 7/16” dia. and assemble the outside and inside step plates to the section using (2) #8 x 1-5/8” screws.
CAUTION: DO NOT DRILL THROUGH OR ENLARGE HOLES ON THE INSIDE OF THE DOOR SECTION.
Bottom section inside
8” Max. mounting height
Tools Required: Tape measure, Power drill, Drill bits, 7/16” Wrench, Phillips head screwdriver, Saw horses
Bottom section outside
Holes enlarged
Pre-punched holes
Inside step plate
to 7/16” diameter
Outside step plate
(2) #8 x 1-5/8” screws
Lift Handle
9
NOTE: Doors with a Keyed lock do not require this lift handle. Locate the inside center 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 lock (2nd) section.
IMPORTANT: THE DISTANCE BETWEEN THE STEP PLATE AND THE MIDDLE OF THE LIFT HANDLE MUST BE 20” MINIMUM TO 30” MAXIMUM. IF NECESSARY REPOSITION THE UPPER LIFT HANDLE TO STAY WITHIN THE REQUIRED DIMENSION.
Using the lift handle holes as a template, drill (2) 9/32” dia. holes through the lock section. Enlarge the holes from the outside the door to 1/2” dia.
CAUTION: DO NOT DRILL THROUGH OR ENLARGE HOLES ON THE INSIDE OF THE DOOR SECTION.
Assemble the outside and inside lift handles to the lock section using (2) spacers, (2) 1/4” ­20 x 2-1/2” carriage bolts and (2) 1/4” - 20 hex nuts.
Tools Required: Tape measure, Pencil, Power drill, 9/32”/1/2” Drill bits, 1/4” Wrench, Saw horses
End stile
11
Page 12
Lock
Lock
section
inside
(2) 1/4”-20
Hex nuts
Lift handle
4”
1/2” Diameter
holes
(2)
Spacers
section outside
(2) 1/4”-20 x 2-1/2” Carriage bolts
Lift handle
Bottom Section
10
Center the bottom section in the door opening. Level the section using wooden shims (if necessary) under the bottom section. When the bottom section is leveled, temporarily hold it in place by driving a nail into the jamb and bending it over the edge of the bottom section on both sides.
Tools Required: Level, Wooden shims (if necessary)
Flag angle
Vertical
track
assembly
Jamb bracket
Bottom section
5/16” x 1-5/8” Lag screws
Track rollers
Floor
12R FA
15R FA 15R QI12R QI
Flag angle lag screw locations
3/8” to 5/8”
Spacing
Bottom section
Vertical track
Track roller
Weather seal
Level
Bottom section
Wooden shims
(If necessary)
Vertical Tracks
11
NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag Angles, Riveted Vertical Track Assemblies or you may have Angle Mount Vertical Track Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Flag Angles / Vertical Track Assemblies you have.
IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.
IMPORTANT: THE TOPS OF THE VERTICAL TRACK ASSEMBLIES MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK AS­SEMBLY ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.
Position the left hand vertical track assembly over the track rollers of the bottom section. Make sure the counterbalance lift cable is located between the track rollers and the door jamb. Drill 3/16” pilot holes into the door jamb for the lag screws.
FOR QUICK INSTALL FLAG ANGLES OR FULLY ADJUSTABLE FLAG ANGLES: Loosely fasten jamb brackets and flag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing, between the bottom section and vertical track. Hang counterbalance lift cable over flag angle. Repeat same process for other side.
Tools Required: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure, Level, Step ladder
FOR RIVETED VERTICAL TRACK ASSEMBLY: Loosely fasten jamb brackets and flag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing as shown between the bottom section and vertical track. Hang counterbalance lift cable over flag angle. Repeat same process for other side.
FOR ANGLE MOUNT VERTICAL TRACK ASSEMBLY: Loosely fasten the slots in the wall angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom slot in the wall angle, maintain 3/8” to 5/8” spacing as shown between the bottom section and vertical track. Hang counterbalance lift cable over angle mount. Repeat same process for other side.
Wall
angle
Slot
Angle mount vertical track
assembly
5/16” x 1-5/8”
Lag screws
Vertical
track
Bottom section
Vertical
track
Jamb
bracket
Riveted
vertical track
assembly
Flag
angle
5/16” x 1-5/8”
Lag screws
Bottom section
Bottom section
Vertical track Floor
3/8” to 5/8”
Spacing
Flag angle lag screw
locations
Stacking Sections
12
NOTE: Refer to door section identification, located in the pre-installation section of this manual to determine what size sections you need to use as your lock (second) section, inter­mediate (third) section, intermediate (fourth) section, intermediate (fifth) section, intermediate (sixth) section and intermediate (seventh) section. Measure your sections to make sure they are the correct height as indicated on the chart.
NOTE: Make sure graduated end and center hinges are flipped down, when stacking another section on top.
Place short stem track rollers into graduated end hinges of remaining sections. NOTE: Larger doors will use long stem track rollers with double graduated end hinges. With assistance, lift second section and guide the track rollers into the vertical tracks. Lower
section until it is seated against bottom section. Flip hinges up. Fasten center hinge(s) first; then end hinges last using 1/4” - 20 x 11/16” self-tapping screws.
Repeat same process for other sections, except top section. IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE
Tools Required: Power drill, 7/16” Socket driver
12
Page 13
SECURING WITH 1/4” - 20 X 5/8” SELF-TAPPING SCREWS. THERE SHOULD BE NO GAP BETWEEN THE HINGE LEAFS AND THE SECTIONS.
NOTE: Install lock at this time (sold separately). See optional installation step, Side Lock.
Lock section
Vertical tracks
Short stem track roller
14
(4) 1/4”-20 x 11/16”
Self drilling screws
Top fixture
base
5/16”-18
Hex nut
Top Section
Tools Required: Hammer, Step ladder, Tape measure
End cap
Top section
5/16”-18 x 3/4”
Carriage bolt
Top fixture
slide
Left end hinge
Single end
hinges
Bottom section
1/4”-20 x 11/16” Self drilling screw locations
Upper hinge
leafs
Double end
hinges
Intermediate hinge(s)
Double end
hinges
Right
end hinge
Single end
hinges
Top Fixtures
13
NOTE: Depending on your door, you may have Top Fixture Bases and Top Fixture Slides or you may have Top Fixture Assemblies. Refer to Illustrations / Package Contents / Parts Breakdown, to determine which Top Fixtures you have.
Starting on the left hand side, align the top fixture base 3” down from the top section or below strut and even with the edge of the top section. The slotted half of the top fixture base should be facing upwards. Fasten to section through end cap using (4) 1/4” - 20 x 11/16” self drilling screws. Insert short stem track roller into top fixture slide. Repeat for other side.
NOTE: If needed, ensure the top fixture slides are able to slide back and forth along the top fixture bases. If needed, loosen the (2) 1/4” - 20 flange hex nuts. The top fixture slide will be tightened and adjusted later, in step, Adjusting Top Fixtures.
Top section
3”
Top fixture
slide
Top fixture
base
Starting on the left hand side, align the top fixture base on top of the corner of the top section and even with the edge of the section. Fasten to section through end cap using (4) 1/4” - 20 x 11/16” self drilling screws. Loosely secure the top fixture slide to the top fixture base using (1) 5/16” - 18 x 3/4” carriage bolt and (1) 5/16” - 18 hex nut. The top fixture assembly will be tightened and adjusted later, in step, Adjusting Top Fixtures. Insert short stem track roller into top fixture slide. Repeat for other side.
Tools Required: Power drill, 7/16” Socket driver, Saw horses
(2) 1/4”-20 Flange
hex nuts
(4) 1/4”-20 x 11/16”
Self drilling screws
End
Short stem track roller
cap
Top section
Strut
End
(4) 1/4”-20 x 11/16”
cap
Self drilling screws
Top
section
Place the top section in the opening. Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section. Now, flip up the hinge leaves, hold tight against section, and fasten center hinges first and end hinges last (refer to step, Stacking Sections). Vertical track alignment is critical. Position flag angle or wall angle between 1-11/16” (43 mm) to 1-3/4” (44 mm) from the edge of the door; tighten the bottom lag screw. Flag angles or wall angles must be parallel to the door sections. Repeat for other side.
IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES OR WALL ANGLES MUST BE DOOR WIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERA­TION.
FOR QUICK INSTALL TRACK: Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Repeat for other side.
FOR FULLY ADJUSTABLE TRACK OR RIVETED TRACK: Complete the vertical track instal­lation by securing the jamb bracket(s) and tightening the other lag screws. Push the vertical track against the track rollers so that the track rollers are touching the deepest part of the curved side of the track; tighten all the track bolts and nuts. Repeat for other side.
FOR ANGLE MOUNT TRACK: Complete the vertical track installation by securing the jamb bracket(s) and or tightening the other lag screws. Push the vertical track against the track rollers so that the track rollers are touching the deepest part of the curved side of the vertical track, as shown. Repeat for other side.
Door width + 3-3/8” to 3-1/2”
Top of flag angle or Top of wallangle assembly
Nail
Top section
1-11/16” to 1-3/4”
Flag angle
Top section
Flag angle or wallangle assembly
Vertical track against track rollers
Drawbar Operator Bracket
15
IMPORTANT: WHEN CONNECTING A TROLLEY TYPE GARAGE DOOR OPENER TO THIS DOOR, A WAYNE-DALTON OPERATOR/ TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR IF ONE HAS BEEN PROVIDED, ALONG WITH ANY STRUTS PROVIDED WITH THE DOOR (IF A WAYNE-DALTON OPERATOR/ TROLLEY BRACKET WAS NOT PROVIDED WITH YOUR DOOR, THAN USE THE ONE PROVIDED BY YOUR OPERATOR MANU­FACTURER). THE INSTALLATION OF THE OPERATOR MUST BE ACCORDING TO MANUFAC­TURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY.
NOTE: For retro fit applications, the drawbar operator bracket must be aligned with an exist­ing operator.
NOTE: Refer to illustrations to determine which top fixtures were supplied with your door. Follow the corresponding step below:
Place the bottom half inside the top half and flush against the inside surface of the top section. Adjust both the top and bottom halves out as far apart as possible on the section surface. Secure the drawbar operator bracket bottom half and the top half together using (4) 5/16” - 18 x 1/2” carriage bolts and (4) 5/16” - 18 flange hex nuts.
NOTE: Install the 5/16” - 18 x 1/2” carriage bolts and the 5/16” - 18 flange hex nuts as far apart as possible, prior to securing both top and bottom halves together.
Tools Required: Power drill, 7/16” Socket driver, Level, Tape measure, Step ladder
13
Page 14
Now, locate the center of the top section and align the center of the holes in the drawbar op­erator bracket assembly with the top section center line. Align the drawbar operator bracket assembly vertically.
NOTE: For retro fit applications, the drawbar operator bracket assembly must be aligned with an existing operator.
Slide the top halve of the drawbar operator bracket assembly under the strut, keeping the drawbar operator bracket assembly aligned with the center line. Remove the strut’s screws, if necessary and attach to the top section (through strut if necessary) using (3) 1/4” - 20 x 7/8” self drilling screws.
NOTE: If your door lacks a strut on the top section, ignore the previous paragraph. Attach the bottom halve of the drawbar operator bracket to the section surface using (3) 1/4”
- 20 x 5/8” self drilling screws. NOTE: When attaching drawbar operator bracket to top section with strut, apply additional
pressure to thread into the strut.
(3) 1/4”- 20 x 7/8” Self-drilling screws
(4) 5/16”- 18 x 1/2”
Carriage bolts and
(4) 5/16”- 18 flange
Top half
Strut
Locate the center of the top section. Position the drawbar operator bracket under the strut (if applicable) or align the drawbar operator bracket top edge with the top edge of the top section, as shown. Attach the drawbar operator bracket using (3) 1/4” - 20 x 7/8” self-drilling screws (as shown).
Top section
Drawbar operator
bracket
Bottom half
operator bracket
Drawbar
Strut
stripes
Pin
hex nuts
(3) 1/4” -20 x 5/8” Self-drilling screws
(3) 1/4”- 14 x 7/8” Self-drilling screws
Horizontal Tracks
16
NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag Angles, Riveted Vertical Track Assemblies or you may have Angle Mount Vertical Track Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Flag Angles / Vertical Track Assemblies you have.
Tools Required: Ratchet wrench, 9/16” Socket, 9/16” Wrench, level, Step ladder
WARNINGWARNING
DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR, AS OUTLINED IN STEP, REAR BACK HANGS, OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY.
IF YOU HAVE QUICK INSTALL FLAG ANGLES: To install horizontal track, place the curved
end over the top track roller of the top section. Align key slot of the horizontal track with the Quick Install tab of the flag angle. Push curved portion of horizontal track down to lock in place.
Flag angle
3/8”-16
Flag angle Horizontal
track Quick
Install tab
IF YOU HAVE FULLY ADJUSTABLE FLAG ANGLES: To install horizontal track, place the curved end over the top track roller of the top section. Align the bottom of the horizontal track with the top of the vertical track. If you have Quick Install horizontal track, tighten the horizontal track to the flag angle with a stud plate and (2) 1/4” - 20 flange hex nuts. If you have Universal horizontal track, tighten the horizontal track to the flag angle with (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 flange hex nuts.
Quick Install
horizontal
track
1/4”-20 Flange hex nuts
Flag angle upper slot
IF YOU HAVE RIVETED TRACK ASSEMBLIES OR ANGLE MOUNT VERTICAL TRACK ASSEMBLIES: To install horizontal track, place the curved end over the top roller of the top
section. Align the bottom of the horizontal track with the top of the vertical track. Tighten the horizontal track to the Flag Angle / Angle Mount with (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 flange hex nuts.
Horizontal track
1/4”-20 Flange hex nuts
Rivited flag angle upper slot
Horizontal
track
1/4”-20
Flange hex
nuts
Flag angle
Next level the horizontal track assembly and bolt the horizontal track angle to the first encountered slot in the flag angle / angle mount using (1) 3/8” - 16 x 3/4” truss head bolt and (1) 3/8” - 16 hex nut. Repeat for other side. Next remove the nail that was temporarily holding the top section in place, installed in step, Top Section.
IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION.
Quick Install tab in place
Tracks flush
Key slot
Fully Adjustable horizontal track
1/4”-20 Flange hex nuts
Flag angle upper slot
Stud plate
1/4”-20 x 9/16” Track bolts
1/4”-20 Flange hex nuts
1/4”-20 x 9/16”
Track bolts
Rivited flag angle
3/8”-16 Hex nut
Hex nut
Horizontal track angle
3/8”-16 x 3/4” Truss head bolt
Horizontal track angle
1/4”-20 x 9/16” Track bolts
Horizontal
track
Angle
mount
Horizontal
track angle
Horizontal
1/4”-20 x 9/16”
Track bolts
3/8”-16 Hex nut
track
3/8”-16 x 3/4” Truss head bolt
3/8”-16 Hex nut
3/8”-16 x 3/4” Truss head bolt
3/8”-16 x 3/4” Truss head bolt
Horizontal track angle
Angle
mount
Adjusting Top Fixtures
17
NOTE: Depending on your door, you may have Top Fixture Bases and Top Fixture Slides or you may have Top Fixture Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Top Fixtures you have.
With horizontal tracks installed, you can now adjust the top fixtures. Vertically align the top section of the door with the lower sections. Once aligned, position the top fixture slide, out against the horizontal track. Maintaining the slide’s position, tighten the (2) 1/4” - 20 flange hex nuts or the (1) 5/16” - 18 hex nut to secure the top fixture slide to the top fixture base. Repeat for other side.
Tools Required: 7/16” Wrench, Step ladder
14
Page 15
Short stem track
roller
Horizontal track
Horizontal
track
Top section
1/4”-20 Flange hex nut
Top fixture slide
Top section
Top
fixture
slide
NOTE: Prior to fastening center bracket(s) into the door jamb, pilot drill using a 3/16” drill bit. NOTE: Refer to Package Contents / Parts Breakdown, to determine if your door came with a
coupler assembly. If your door came with a coupler assembly, the mounting surface needs to be a minimum of 17” wide. The two center bearing brackets will need to be spaced 12” to 14” apart at the center of the door, as shown.
NOTE: If your door came with (4) springs, each of the outer springs mounting surface will need to be a minimum of 3” wide.
NOTE: If needed, measure the diameter of your springs. If you have a one piece shaft with 3-3/4” diameter springs, they do not share center brackets and do not have a coupler as­sembly.
First, locate the center of the door. Mark a vertical pencil line on the mounting surface above the door, at the center. Measure from the center of the bearing, in one of the end bearing brackets, downwards, to the top the door. Using that measurement, measure that distance upwards from the top of the door to the mounting surface and mark a horizontal pencil line which intersects the vertical pencil line.
Short stem track roller
5/16”-18
Hex nut
End Bearing Brackets
18
NOTE: Refer to Package Contents / Parts Breakdown, to determine which End Bearing Brackets you have.
NOTE: Prior to fastening end bearing brackets into the door jamb, pilot drill using a 3/16” drill bit.
IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT.
NOTE: Depending on your door’s configuration you may have to break the end bearing brackets apart.
NOTE: End bearing brackets are right and left hand. Attach the left hand end bearing bracket through either the end bearing bracket’s upper or
lower slots to the left hand horizontal track angle using (2) 3/8” - 16 x 3/4” truss head bolts and (2) 3/8” - 16 nuts.
IMPORTANT: THE END BEARING BRACKET’S LOWER SLOTS ARE USED ON DOORS WITH 12” RADIUS TRACK; THE UPPER SLOTS ARE USED ON DOORS WITH 15” RADIUS TRACK.
Secure the top of the end bearing bracket to the jamb using 5/16” x 1-5/8” lag screw(s). Repeat the same process for right hand side.
(2) 3/8”-16 Hex nuts
Tools Required: Step ladder, Power drill, 3/16” Drill bit, Ratchet wrench, 7/16” Socket driver, 9/16” Socket, 9/16” Wrench
Left end bracket
(2) 3/8”-16 x 3/4” Truss head bolts
Upper slots Lower slots
(1) 5/16” x 1-5/8” Lag screw
Horizontal track angle
Typicall center bracket
Typicall center of end bearing bracket
Mounting surface
Vertical line
Horizontal line
Equal distance (top of door section to horizontal line)
IF YOUR DOOR DID NOT COME WITH A CENTER COUPLER ASSEMBLY OR TORSION SPRINGS LESS THAN 3-3/4” ID: Mark a vertical pencil line on the mounting surface above
the door, at the center. Align the edge of the center bracket with the vertical pencil line and the center of the center bracket with the horizontal pencil line; this is to ensure the torsion shaft is level between the center and end bearing brackets.
NOTE: On some single spring doors, the single spring can be longer than half the opening width. If your spring is longer, then the center bracket must be mounted off center for the spring to fit properly. Measure spring length to determine appropriate center bracket location.
Mounting
surface
(3” Minimum)
Vertical
line
Horizontal
line
Center bracket
bushing assembly
(2) 5/16” x 1-5/8”
Lag screws
Vertical
line
Mounting surface
(3” Minimum)
(2) 5/16” x 1-5/8”
Lag screws
Bend back and fourth to
seperate the (2) end
bearing brackets
Left end
(2) 3/8”-16
Hex nuts
bracket
(2) 3/8”-16 x 3/4”
Truss head bolts
Upper
slot
Lower slots
(3) 5/16” x 1-5/8”
Lag screws
Horizontal
track angle
Center Bracket
19
NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s) came with your door.
Tools Required: Step ladder, Power drill, 7/16” Socket driver, 3/16” Drill bit, 1/4” Torx bit, Level, Tape measure, Pencil
Horizontal
line
(1) 5/16” X 2” or (1) 5/16” x 1-5/8” Tamper-resistant lag screw
IF YOUR DOOR DID COME WITH A CENTER COUPLER ASSEMBLY OR 3-3/4” ID TOR­SION SPRINGS: Mark a vertical pencil line on the mounting surface above the door, at the
center. Split the difference up and position the (2) center bearing brackets apart from each other. Mark two vertical pencil lines, one for each center bearing bracket onto the mounting surface above the door.
NOTE: If your door came with a center coupler assembly or if it utilizes 3-3/4” springs, the springs will not share a center bracket.
NOTE: If your door has (4) springs, split the distance between the center of the door and the end bracket on each side to locate the intermediate center brackets.
Attach each of the center bracket(s) 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 A 5/16” X 1-5/8” TAMPER-RESISTANT LAG SCREW INSTEAD OF THE 5/16” X 2” TAMPER-RESISTANT LAG SCREW IF MOUNTING SURFACE IS MOUNTED OVER MASONRY. TAMPER-RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BRACKET(S).
15
Center bearing bracket
assembly
Page 16
Mounting surface
Center bearing
(17” Minimum)
Vertical
line
(2) 5/16” x 1-5/8”
Lag screws
Horizontal
line
Center
door
(1) 5/16” X 2” or (1) 5/16” x 1-5/8” Tamper-resistant
of
†
lag screw
Vertical line
(2) 5/16” x 1-5/8”
Lag screws
† (2) Center bearing
brackets spaced 6” to 7”
apart from the center of
the door.
Torsion Spring Assembly
20
NOTE: Refer to the Package Contents and or Parts Breakdown to determine if your door came with a coupler assembly.
IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT.
IMPORTANT: Identify the torsion 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.
IMPORTANT: ON SINGLE SPRING APPLICATIONS, ONLY A LEFT HAND WOUND (BLACK WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE IS REQUIRED.
NOTE: The set screws used on all torsion winding cones and cable drums are now colored red. DO NOT identify right and left hand by the set screw color.
IF YOU DON’T HAVE A COUPLER ASSEMBLY:
Facing the inside of the door, lay the torsion shaft / torsion keyed shaft on the floor. Lay the torsion spring with the black winding cone and the black cable drum at the right end of the torsion shaft / torsion keyed shaft. Lay the torsion spring with the red winding cone and the red cable drum at the left end of the torsion shaft / torsion keyed shaft.
Slide the center bracket bearing / center bracket bushing onto the torsion shaft / torsion keyed shaft followed by the torsion springs and cable drums.
IMPORTANT: THE CENTER BRACKET BEARING / CENTER BRACKET BUSHING, TORSION SPRINGS, AND CABLE DRUMS MUST BE POSITIONED, AS SHOWN.
Left hand cable drum, red
With assistance, pick up the torsion spring assembly and slide one end of the torsion shaft / torsion keyed shaft through one end bearing bracket. Lay the middle of the torsion shaft / torsion keyed shaft into the center bracket. Slide the other end of the torsion shaft / torsion keyed shaft into the other end bearing bracket. Position the torsion shaft / torsion keyed shaft so that equal amounts of the shaft extend from each end bearing bracket.
Tools Required: 3/8” Wrench, 9/16” Wrench, Step Ladder
Torsion shaft
black winding cone
Center bearing
Right hand wound, red winding cone (left hand side)
Left hand end bearing bracket
Torsion shaft
Equal spacing
Center bracket bushing
Center bracket
cable drum,
Left hand wound,
(right hand side)
IMPORTANT: ON SINGLE
SPRING APPLICATIONS,
ONLY A LEFT HAND WOUND
(BLACK WINDING CONE),
WHICH GOES ON THE RIGHT
HAND SIDE IS REQUIRED.
Right hand end bearing bracket
Right hand
black
the torsion keyed shaft. Next on the right hand side, lay the other coupler half, center bearing, the torsion spring with the black winding cone, and the black cable drum at the right end of the torsion keyed shaft.
Slide the coupler halves, center bearings onto the torsion keyed shafts followed by the torsion springs and the cable drums, as shown.
IMPORTANT: THE COUPLER HALVES, CENTER BEARINGS, TORSION SPRINGS, CABLE DRUMS MUST BE POSITIONED, AS SHOWN.
Slide the flat edge of the couple half flush with the side edge of the torsion keyed shaft. Insert (1) key into the slot of both the coupler half and the slot in the torsion keyed shaft. Tighten the (2) set screws and the locking nut to secure the coupler half to the torsion keyed shaft, as shown.
NOTE: Tighten the set screws to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten set screws one full turn). Repeat the same process for the other coupler half.
Set screws
and Lock
nut
Center coupler assembly
(3) 3/8” - 16 x 1-3/4” Hex head screws
and (3) 3/8” - 16 Nylon hex lock nut
Red cable drum
(left hand side)
Torsion keyed shaft
Set screws
and Lock
nut
Center coupler assembly
(3) 3/8” - 16 x 1-3/4” Hex head screws
and (3) 3/8” - 16 Nylon hex lock nut
Red cable drum
(left hand side)
Center bearing
Torsion keyed shaft
Coupler
halves
Right hand wound, red winding cone (left hand side)
Coupler
halves
Right hand wound, red winding cone (left hand side)
Center
bearing
Center
bearing
Torsion
keyed
shaft
Coupler
halves
Center
bearing
Coupler
halves
Black cable drum
(right hand side)
Set screws
and Lock nut
Key
Black cable drum
(right hand side)
Torsion keyed shaft
Set screws
and Lock nut
Key
Center
bearing
Left hand wound,
black winding cone
(right hand side)
Key
Coupler halves
assembled
Left hand wound,
black winding cone
(right hand side)
Key
Coupler halves
assembled
With assistance and starting on the left hand side of door, pick up the left hand torsion spring assembly and slide one end of the torsion keyed shaft through the end bearing bracket. Lay the other side of the torsion keyed shaft into the center bracket. Repeat the same process for the right hand torsion spring assembly. Position both torsion keyed shafts so that equal amounts of the shafts extend from each end bearing brackets.
Equal spacing
Equal
spacing
Torsion
keyed
shaft
Right
hand end
bearing bracket
brackets
Center
bearing
Right hand wound, red winding cone (left hand side)
Torsion
keyed
shaft
Coupler
half
IF YOU HAVE A COUPLER ASSEMBLY:
Disassemble the coupler assembly by removing the (3) 3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8”-16 nylon hex lock nuts from the coupler halves. Loosen the set screws. Set the components aside. Facing the inside of the door, lay the (2) torsion keyed shafts on the floor. One torsion keyed shaft on the left hand side and the other torsion keyed shaft on the right hand side. Starting on the left hand side, lay one of the coupler halves, the center bearing, torsion spring with the red winding cone and the red cable drum at the left end of
16
Left hand end
bearing bracket
Page 17
Left hand end bearing bracket
Torsion keyed shafts
Equal spacing
Center
bracket
bushing
Center bracket
Right hand end bearing bracket
Torsion Spring Attachment
21
NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s) came with your door.
NOTE: Refer to Package Contents / Parts Breakdown, to determine if your door came with a coupler assembly.
IMPORTANT: THE SPRING WARNING TAG(S) SUPPLIED MUST BE SECURELY ATTACHED TO THE STATIONARY SPRING CONE(S) IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING WARNING TAG BE REQUIRED, CONTACT WAYNE-DALTON FOR FREE REPLACEMENTS.
NOTE: Measure the diameter of your springs. If your spring diameter is 3-3/4”, the springs do not share center brackets. If your spring diameter is either 2” or 2-5/8”, then two springs will share the same center bracket, unless a coupler assembly is provided.
IF YOU DON’T HAVE A COUPLER ASSEMBLY:
Slide center bracket bushing into the spring. Align the stationary spring cone(s) with the holes in the center bracket bushing assembly. Secure the torsion spring(s) to the center bracket bushing assembly with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts.
IF YOU HAVE A COUPLER ASSEMBLY:
Slide center bracket bushing into the spring. Align the stationary spring cone with the holes in the center bracket. Secure the torsion spring to the center bracket with (2) 3/8”-16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts. Repeat the same process for the other center bearing bracket.
At the middle of the two center bearing brackets, re-assemble the coupler assembly by loosely fastening the coupler halves together using the (3) 3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8” - 16 nylon hex lock nuts, as shown.
NOTE: Ensure both torsion keyed shafts have equal amounts of the shafts extending from each end bearing bracket.
Typical center bracket
Tools Required: Step Ladder, Ratchet Wrench, 9/16” Socket, 9/16” Wrench
Stationary spring cone
Torsion spring
(3) 3/8” - 16 x 1-3/4”
hex head screws and
(3) 3/8” - 16 Hex nuts
Stationary
spring cone
Center bracket
Torsion
spring
Coupler halves
(2) 3/8”-16 x 1-1/2”
Hex head bolts and (2)
3/8”-16 Hex nuts
Coupler
assembly
Torsion
spring
Center
bracket
Counterbalance Lift Cables
22
Starting on the left hand side, thread the counterbalance lift cable up and around the front side of the left hand cable drum.
IMPORTANT: VERIFY THAT THERE ARE NO COUNTERBALANCE LIFT CABLE OBSTRUCTIONS. NOTE: Always assemble the left hand cable and cable drum first to help maintain equal cable
tension on both sides of the door. Hook the counterbalance lift cable into the left hand cable drum. Slide the left hand cable
drum up against the left hand end bearing bracket. Counterbalance lift cable should terminate at the 3 o’clock position. Tighten the (2) set screws in the drum to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten screws one full turn).
NOTE: If you have torsion keyed shaft(s), insert (1) key into the slot of both the cable drum and the slot in the torsion keyed shaft, as shown.
Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach locking pliers to the torsion shaft and brace locking pliers up against jamb to keep counter­balance lift cable taut. Repeat for right hand side.
IMPORTANT: INSPECT EACH COUNTERBALANCE LIFT CABLE MAKING SURE THEY ARE SEATED PROPERLY ONTO THE CABLE DRUMS AND THAT BOTH COUNTERBALANCE LIFT CABLES HAVE EQUAL TENSION.
Once the counterbalance cables are set and if applicable tighten the coupler assembly together by tightening the (3) 3/8” - 16 nylon hex lock nuts to secure the coupler halves together.
Typicall left hand end bearing bracket
Tools Required: Step Ladder, Locking Pliers, 3/8” Wrench
Typicall left hand cable drum
Torsion shaft / Torsion keyed shaft
Stationary spring cone
Torsion spring
Torsion spring
(2) 3/8”-16 Nuts
Stationary spring cone
Typical center bracket bushing
(2) 3/8”-16 x 1-1/2” Hex head bolts
Spring warning tags
Typical center bracket assembly
Torsion spring
Locking pliers
Counterbalance lift cable
Typicall left hand cable drum
Set screws
Counterbalance
lift cable
Counterbalance lift cable hooked in cable
drum
Jamb
Typicall left hand end bearing bracket
Key
Torsion shaft / Torsion keyed shaft(s)
17
Page 18
Chalking Torsion Spring(s)
23
Draw a chalk line horizontally along the center of the torsion spring coil(s). As the torsion spring is wound, the chalk line will create a spiral. This spiral can be used to count and determine the number of turns that are applied on the torsion spring.
Torsion
shaft
Tools Required: Step Ladder, Chalk
Center
bracket
Original horizontal chalk line, prior
Torsion
spring coils
to winding
Winding
cone
Spirals created after winding
Securing Door for Spring Winding
24
With the door in the fully closed position, place vice clamps / c-clamps onto both vertical tracks just above the third track roller. This is to prevent the garage door from rising while winding springs.
NOTE: Check the following before attempting to wind torsion spring(s): a. Counterbalance lift cables are secured at bottom corner brackets. b. Counterbalance lift cables are routed unobstructed to cable drums. c. Counterbalance lift cables are correctly installed and wound onto cable lift drums. d. Counterbalance lift cables are taut and have equal tension on both sides. e. Cable lift drums are against end bearing brackets and set screws are tight. f. Torsion spring or springs are installed correctly. g. Review the label attached to the spring warning tag, to determine number of spring turns
required. NOTE: Door MUST be closed and locked when winding or making any adjustments to the
torsion spring(s).
Tools Required: Vice Clamps
WARNINGWARNING
FAILURE TO ENSURE DOOR IS IN A CLOSED POSITION AND TO PLACE VICE CLAMP ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.
Winding Bars
(Steel Rods)
C-Clamps
Size Of Winding Bar
(Inches)
1/2” dia. x 18”
5/8” dia. x 24”
Spring Diameter
Used On
2” and 2-5/8”
3-3/4”
WARNINGWARNING
USE ONLY SPECIFIED WINDING BARS, AS STATED IN STEP SECURING DOOR FOR SPRING WINDING. DO NOT SUBSTITUTE WITH SCREWDRIV­ERS, PIPE, ETC. OTHER TOOLS MAY FAIL OR RELEASE FROM THE SPRING CONE AND CAUSE SERIOUS PERSONAL INJURY.
WARNINGWARNING
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.
Position a ladder slightly to the side of the spring so that the winding cone is easily acces­sible, and so your body is not directly in 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.
Door Height Approximate Spring Turns
6’0” 6-7/8
6’3” 7-1/8
6’6” 7-1/4
6’8” 7-3/8
6’9” 7-1/2
7’0” 7-5/8
7’3” 7-7/8
7’6” 8
7’9” 8-1/4
8’0” 8-3/4
Alternately inserting the winding rods into the holes of the spring winding cone, rotate the winding cone upward toward the ceiling, 1/4 turn at a time, until the required number of complete turns for your door height is achieved. As the last 1/8 to 1/4 turn is achieved, securely hold the winding rod and carefully stretch the torsion spring 1/8” - 1/4”. Next while still securely holding the winding rod, tighten both set screws in the winding cone to 14-15 ft. lbs. of torque (once set screws contact the torsion shaft, tighten screws one full turn).
Carefully remove winding rod from winding cone. Repeat for the opposite spring. While holding the door down to prevent it from raising unexpectedly in the event the spring(s) were over-wound, carefully remove the locking pliers from the torsion shaft and vertical tracks.
Adjustments to the number of turns stated may be necessary. If door rises off floor under spring tension alone, reduce spring tension until door rests on the floor. If the door is hard to rise or drifts down on its own, add spring tension.
Torsion spring(s) should be wound in the direction the end coil points.
Torsion
spring(s)
Typical sections
track roller on both sides of
door
Vice clamps above third
Vice clamps / C-Clamps attached to inner
Bottom section
and outer rail of vertical track
Winding Spring(s)
25
Tools Required: Step Ladder, Approved winding bars, 3/8” Wrench, Leather gloves, Safety glasses
WARNINGWARNING
WINDING TORSION SPRING(S) IS AN EXTREMELY DANGEROUS PROCE­DURE AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.
Approved
winding
rod
Winding
cone
Torsion shaft
Spring
coils
Set screws
Approved winding rod
IMPORTANT: CHECK THE WARNING
TAG(S) ATTACHED TO THE SPRING(S)
FOR THE REQUIRED NUMBER OF COMPLETE TURNS, TO BALANCE
HIGH SPRING TENSION CAN CAUSE SERIOUS INJURY OR DEATH.
DO NOT adjust, repair or remove springs or parts to
which springs are connected, such as steel brack­ets, cables, wood blocks, fasteners or other parts of the counterbalance system.
Adjustments or repairs must ONLY be made by a trained door systems technician using proper tools and instructions.
DO NOT remove, cover or paint over this tag. Prod­uct user should inspect this tag periodically for legibility and should order a replacement tag from the door manufacturer, as needed.
102081 REV2 06/24/2010
©Copyright 2010 Overhead Door Corporation
YOUR DOOR.
HIGH SPRING TENSION CAN CAUSE SERIOUS INJURY OR DEATH.
DO NOT adjust, repair or remove springs or parts to
which springs are connected, such as steel brack­ets, cables, wood blocks, fasteners or other parts of the counterbalance system.
Adjustments or repairs must ONLY be made by a trained door systems technician using proper tools and instructions.
DO NOT remove, cover or paint over this tag. Prod­uct user should inspect this tag periodically for legibility and should order a replacement tag from the door manufacturer, as needed.
©Copyright 2010 Overhead Door Corporation
Rear Back Hangs
26
IMPORTANT: HOLD THE DOOR DOWN TO PREVENT IT FROM RISING UNEXPECTEDLY IN THE EVENT THE SPRING(S) WAS OVER-WOUND AND CAUTIOUSLY REMOVE VICE CLAMPS FROM VERTICAL TRACKS.
Raise the door until the top section and half of the next section are in the horizontal track radius. Do not raise door any further since rear of horizontal tracks are not yet supported.
18
Tools Required: Ratchet wrench, Socket: 1/2” 5/8”, Wrench: 1/2” 5/8”, (2) Vice clamps, Tape measure, Level, Hammer, Step Ladder
102081 REV2 06/24/2010
Warning
tag(s)
Page 19
WARNINGWARNING
RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE OR FATAL INJURY.
Clamp a pair of vice clamps onto the vertical tracks just above the second track roller on one side, and just below the second track roller on the other side. This will prevent the door from raising or lowering while installing the rear back hangs.
Using the chart (Perforated Angle Gauge Weight Limitations) below, use the appropriate perforated angle (may not be supplied), (2) 5/16” x 1-5/8” hex head lag screws and (3) 5/16” bolts with nuts (may not be supplied), fabricate rear back hangs for the horizontal tracks. Attach the horizontal tracks to the rear back hangs with 5/16” - 18 x 1” hex bolts and nuts (may not be supplied). Horizontal tracks must be level and parallel with door within 3/4” to 7/8” maximum of door edge.
1.) Check the door for level.
2.) Check the torsion shaft for level.
3.) Check the track spacing.
4.) Check the counterbalance cables for equal tension and proper wrap onto the cable drums.
5.) Check the track for potential obstruction of the track 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.
WARNINGWARNING
EXCEEDING THE RECOMMENDED LISTED DOOR WEIGHT LIMITATIONS OF SPECIFIC GAUGE PERFORATED ANGLES MAY RESULT IN DOOR FALLING WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.
WARNINGWARNING
VERIFY PERFORATED BACK HANG ANGLE LOAD RATINGS WITH BACK HANG ANGLE SUPPLIER.
Perforated Angle Gauge Weight Limitations:
Perforated Angle Gauge Door Weight
2” x 2” x 12 Gauge Door Weight Less Than 800 lbs.
1-1/4” x 1-1/4” x 13 Gauge Door Weight Less Than 305 lbs.
1-1/4” x 1-1/4” x 15 Gauge Door Weight Less Than 220 lbs.
1-1/4” x 1-1/4” x 16 Gauge Door Weight Less Than 175 lbs.
NOTE: If an opener is installed, position horizontal tracks one hole above level when securing it to the rear back hangs.
WARNINGWARNING
KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4” TO 7/8” 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 REAR
BACK HANGS THAT CANTILEVERS 4” OR MORE BEYOND A SOUND FRAMING MEMBER. NOTE: If rear back hangs are to be installed over drywall, use (2) 5/16” x 2” hex head lag
screws and make sure lag screws engage into solid structural lumber.
NOTE: 26” angle must be attached to sound framing members and nails should not be used.
Now, permanently attach the weatherstrips on both door jambs and header. The weather­strips were temporarily attached in Preparing the Opening, in the pre-installation section of this manual.
NOTE: When permanently attaching the weatherstrips to the jambs, avoid pushing the weath­erstrips too tightly against the face of door.
WARNINGWARNING
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 spring turns stated may be necessary. If door rises off floor under spring tension alone, reduce spring tension until door rests on the floor. If the door is hard to rise or drifts down on its own, add spring tension. A poorly balanced door can cause garage door operator operation problems.
To adjust spring tension, fully close door. Apply vice grips to track above third track roller. Insert a winding rod into the winding cone. On single spring doors, counterbalance lift cable tension must be maintained by placing vice grips on torsion shaft before loosening set screws in the winding cone. Push upward on the winding rod 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 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:
Vice clamp
Horizontal
track
Hex bolt must extend into the track to serve as a roller stop
5/16”-18 x 1-1/4”
Horizontal tracks
Sound framing members
Vice clamp
2nd Track roller
Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to ceiling member and parallel to door
(3) 5/16” Bolts and nuts
Perforated angle
19
Page 20
(3) 5/16”
Bolts and nuts
Horizontal
track
Perforated angle
Hex bolt must extend into the
track to serve as a roller stop
5/16”-18 x 1-1/4”
Sound framing members
Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to ceiling member and parallel to door
3/4” To 7/8”
Door edges
Horizontal tracks
3/4” To 7/8”
20
Page 21
Optional Installation
Trolley Arm Hookup
NOTE: If Wayne-Dalton operator / trolley bracket was installed, follow these directions.
Align hole in the door arm with holes in operator bracket tabs, as shown. Attach with 5/16” x 1-3/4” cotter pin and cotter ring.
Drawbar operator
bracket tabs
Cotter ring
5/16” x 1-3/4”
Clevis pin
Cotter ring
5/16” x 1-3/4”
Clevis pin
Door arm
Inside Lock
Install the inside lock on the second section of the door. Secure the lock to the section with (4) 1/4” - 20 x 11/16” self drilling screws. Square the lock assembly with the door section, and align with the square hole in the vertical track. The inside lock should be spaced ap­proximately 1/8” away from the section edge.
IMPORTANT: INSIDE LOCK(S) MUST BE REMOVED OR MADE INOPERATIVE IN THE UN­LOCKED POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR.
Square hole in vertical track
Second section
(4) 1/4”-20 x 11/16”
Side lock
End stile
Self drilling screws
1/8”
Pull Down Rope
WARNINGWARNING
DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH OPERATORS. CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY.
Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the right or left side of jamb. Drill 1/8” pilot hole for no. 6 screw eye. Tie the pull down rope to the no. 6 screw eye and to the bottom corner bracket, as shown.
No. 6 Screw eye
Typical bottom corner bracket
48” to 50” From floor
Pull down rope
Pull down rope
21
Page 22
Maintenance
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 weatherstrips 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 solvent­based cleaners of any kind.
Painting Your Garage Door
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. Re-painting 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.
Operation And Maintenance
OPERATING YOUR GARAGE DOOR:
Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. When correctly installed, your Wayne-Dalton door will operate smoothly.
Always operate your door with controlled movements. Do not slam your door or throw your door into the open position, this may cause damage to the door or its components. If your door has an electric opener, refer to the owner’s manual to disconnect the opener before performing manual door operation below.
Manual door operation:
For additional information on manual garage door operations go to www.dasma.com and reference TDS 165.
IMPORTANT: DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN OPENING AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES / SUITABLE GRIPPING POINTS WHEN OPERATING THE DOOR MANUALLY.
Opening a Door: Make sure the lock(s) are in the unlocked position. Lift the door by using the lift handles / suitable gripping points only. Door should open with little resistance.
Closing a Door: From inside the garage, pull door downward using lift handles / gripping point only or a high friction area only. If you are unable to reach the lift handles/ suitable gripping points only, use pull down rope affixed to the side of door. Door should close completely with little resistance.
Using an electric operator: IMPORTANT: PULL DOWN ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR
MADE INOPERATIVE IN THE UNLOCKED POSITION. When connecting a drawbar (trolley type) garage door operator to this door, an drawbar
operator and or drawbar operator bracket must be securely attached to the top section of the door, along with any struts provided with the door. Always use the drawbar operator and or drawbar operator bracket supplied with the door. To avoid possible damage to your door, Wayne-Dalton recommends reinforcing the top section on models 8000, 8100, 8200 and 9100 doors with a strut (may or may not be supplied). The installation of the drawbar opera­tor must be according to manufacturer’s instructions and force settings must be adjusted properly. Refer to the owner’s manual supplied with your drawbar operator for complete details on installation, operation, maintenance and testing of the operator.
Maintaining Your Garage Door: Before you begin, read all warning labels affixed to the door and the installation instruc-
tions and owner’s manual. Perform routine maintenance steps once a month, and have the door professionally inspected once a year. Review your Installation Instructions and Owner’s Manual for the garage door. These instructions are available at no charge from Wayne-Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at www.
wayne-dalton.com. For additional information on garage door/operator maintenance go to www.dasma.com and reference TDS 151, 167 and 179.
Monthly Inspections:
1. Visual Inspection: Closely inspect jambs, header and mounting surface. Any wood found
not to be structurally sound must be replaced. Inspect the springs, counterbalance lift cables, track rollers, pulleys, rear back hangs and other door hardware for signs of worn or broken parts. Tighten any loose screws and/or bolts. Check exterior surface of the door sections for any minor cracks. Verify door has not shifted right or left in the opening. If you suspect problems, have a trained door system technician make the repairs.
WARNINGWARNING
GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACK­ETS, AND OTHER HARDWARE ATTACHED TO THE SPRINGS ARE UNDER EXTREME TENSION, AND IF HANDLED IMPROPERLY, CAN CAUSE SEVERE OR FATAL INJURY. ONLY A TRAINED DOOR SYSTEMS TECHNICIAN SHOULD ADJUST THEM, BY CAREFULLY FOLLOWING THE MANUFAC­TURER’S INSTRUCTIONS.
WARNINGWARNING
NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR LAG SCREWS ON THE COUNTERBALANCE (END OR CENTER BEARING BRACKETS) SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR. THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY, HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.
TorqueMaster® Plus Springs: Pawl knob(s) (located on the TorqueMaster® end brackets above the door) should be engaged to prevent the door from rapidly descending in case of spring failure or forceful manual operation.
Torsion Springs: The torsion springs (located above the door) should only be adjusted by a trained door systems technician. DO NOT attempt to repair or adjust torsion springs yourself.
Extension Springs: A restraining cable or other device should be installed on the extension spring (located above the horizontal tracks) to help contain the spring if it breaks.
2. Door Balance: Periodically test the balance of your door. If you have a garage door drawbar operator, use the release mechanism so you can operate the door by hand when do­ing this test. Start with the door in the fully closed position. Lift the door to check its balance. Adjust TorqueMaster® or Extension spring(s), if door lifts by itself (hard to pull down) or if door is difficult to lift (easy to pull down). DO NOT attempt to repair or adjust Torsion Springs yourself. To adjust TorqueMaster® or Extension spring(s), refer to your installation instructions
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and owner’s manual. If in question about any of the procedures, do not perform the work. Instead, have it adjusted by a trained door systems technician.
3. Lubrication: The door should open and close smoothly. Ensure the door track rollers are rotating freely when opening and closing the door. If track rollers do not rotate freely, clean the door tracks, removing dirt and any foreign substances. Clean and lubricate (use a non-silicon based lubricant) graduated end hinges, center hinge(s), steel track rollers, bearings and torsion spring(s) (torsion spring coil surfaces). DO NOT lubricate plastic idler bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difficult use a graphite dust to lubricate.
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Warranty
Limited Warranty
Models 8300 and 8500
Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants to the original purchaser of the Models 8300 and 8500 (“Product”), subject to all of the terms and conditions hereof, that the Product and all components thereof will be free from defects in materials and workmanship for the following period(s) of time, measured from the date of installation:
Limited Lifetime Warranty* on the Product sections against:
• The Product becoming inoperable due to rust-through of the steel skin from the core of the Product 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.
• Peeling of the original paint as a result of a defect in the original paint or in the application of the original paint coating.
• The Product hardware and tracks (except springs).
ONE (1) YEAR on those component parts of the Product not covered by the preceding provisions of this Warranty. Seller’s obligation under this warranty is specifically limited to repairing or replacing, at its option, any part which is determined by Seller to be defective during
the applicable warranty period. Any labor charges are excluded and will be the responsibility of the purchaser.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty is made to the original purchaser of the Product only, and is not transferable or assignable. This warranty applies only to Product installed in a residential or other non-commercial application. It does not cover any Product installed in commercial or industrial building applications. This warranty does not apply to any unauthorized alteration or repair of the Product, or to any Product or component which has been damaged or deteriorated due to misuse, neglect, accident, failure to provide necessary maintenance, normal wear and tear, acts of God, or any other cause beyond the reasonable control of Seller or as a result of having been exposed to toxic or abrasive environments, including blowing sand, salt water, salt spray and toxic chemicals and fumes.
ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN TIME TO THE APPLICABLE WARRANTY PERIOD REFLECTED ABOVE. NO WARRANTIES, WHETHER EXPRESS OR IMPLIED, WILL APPLY AFTER THE LIMITED WARRANTY PERIOD HAS EXPIRED. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.
IN NO EVENT SHALL SELLER BE RESPONSIBLE FOR, OR LIABLE TO ANYONE FOR, SPECIAL, INDIRECT, COLLATERAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL DAMAGES, even if Seller has been advised of the possibility of such damages. Such excluded damages include, but are not limited to, loss of use, cost of any substitute product, or other similar indirect financial loss. 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.
Claims under this warranty must be made promptly after discovery, within the applicable warranty period, and in writing to the authorized distributor or installer whose name and address appear below. The purchaser must allow Seller a reasonable opportunity to inspect any Product claimed to be defective prior to removal or any alteration of its condition. Proof of the purchase and/or installation date, and identification as the original purchaser, may be required. There are no established informal dispute resolution procedures of the type described in the Magnuson-Moss Warranty Act.
• SELLER: _______________________________________________________________________
• SELLER’S ADDRESS: _______________________________________________________________________
_______________________________________________________________________
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Thank you for your purchase.
PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE
Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.
AFTER INSTALLATION IS COMPLETE, FASTEN THIS
MANUAL NEAR GARAGE DOOR FOR EASY REFERENCE.
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