Wayne-Dalton 8300, 8500 User Manual

T a b l e O f C o n t e n t s

GARAGE DOORS & OPENERS

8300/8500

t O r S i O n

Standard Lift

inStaLLatiOn inStructiOnS and Owner’S manuaL

Parts Breakdown 2 Pre-Installation 3

Important Safety Instructions 3 Tools Required 3 Package Contents 3 Door Section Identiﬁcation 4 Removing an Existing Door 4 Preparing the Opening 4

Installation 6 Optional Installation 15

Trolley Arm Hookup 15 Side Lock 15 Pull Rope 15

Maintenance 16

Cleaning Your Garage Door 16 Painting Your Garage Door 16 Operation and Maintenance 16

Warranty 18 Dealer Locator Information 20

IMPORTANT NOTICES!

Wayne-Dalton highly recommends that you read and fully understand the Installation Instructions and Owner’s Manual before you attempt this installation.

To avoid possible injury, read the enclosed instructions carefully before installing and operating the garage door. Pay close attention to all warnings and notes. After installation is complete, fasten this manual near garage door for easy reference.

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 No.

347540 NEW 07/20/2011

PARTS BREAKDOWN

NOTE: The illustrations shown on this page are general representations of the door parts. Each speciﬁc door models may have unique variations.

J1.

J7.

J5.

J9.

J3.

C1.

A1.

B1.

D1.

C1.

J8.

F2.

F1.

D2.

C2.

J9.

J6.

J7.

C1.

F2.

F1.

J7.

E1.

E2.

E3.

E4.

L1.

K1.

A1.

J4.

I2.

H1.

H2.

B1.

G1.

I4.

G2.

K2.

I3.

L1.

A. FLAG ANGLES:

A1. Left and Right Hand Flag Angles

B. JAMB BRACKETS:

B1. Left and Right Hand Jamb Brackets

C. TRACK ROLLERS:

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 FIXTURES:

F1. Top Fixture Bases F2. Top Fixture Slides

G. STRUT(S) (AS REQUIRED):

G1. Struts (3” U-shaped) G2. Struts (3” U-shaped)

H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):

H1. Top Halve Drawbar Operator Bracket H2. Bottom Halve Drawbar Operator Bracket

I. TRACKS:

I1. Left Hand Horizontal Track Assembly I2. Right Hand Horizontal Track Assembly I3. Left Hand Vertical Track I4. Right Hand Vertical Track

J. TORSION SPRING ASSEMBLY:

J1. Spring Anchor Bracket / Center Bracket J2. Torsion Shaft J3. Left Hand Head Plate / End Bearing Bracket J4. Right Hand Head Plate / End Bearing Bracket J5. Left Hand Cable Drum J6. Right Hand Cable Drum J7. Right Hand and Left Hand Torsion Springs (As Required) J8. Spring Anchor Bushing / Center Bracket Bushing J9. Counterbalance Lift Cables

K. REAR BACK HANGS:

K1. Left Hand Rear Back Hangs Assemblies K2. Right Hand Rear Back Hangs Assemblies

L. BOTTOM CORNER BRACKETS:

L1. Left Hand Bottom Corner Bracket L2. Right Hand Bottom Corner Bracket

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To ﬁnd your local Wayne-Dalton dealer,

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

Pre-Installation

Important Safety Instructions

DEFINITION OF KEY WORDS USED IN THIS MANUAL:

WARNING WARNING

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

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

INSTRUCTIONS.

IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION. NOTE: Information assuring proper installation of the door.

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 caus-

ing 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 neces-

sary 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 altera-

tion 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

Vertical tracks RH/LH

Horizontal tracks RH/LH

Flag angles RH/LH

Top ﬁxture assemblies

(as required)

Spring anchor bushing /

Track rollers

Cable drums RH/LH

Center bracket bushing

Bottom corner brackets

RH/LH (as required)

Drawbar operator bracket

(if included)

Torsion springs RH/LH

Bottom corner brackets

RH/LH (as required)

Jamb brackets

(as required)Graduated hinges

Spring anchor bracket /

Center bracket (as required)

Head plates / End bearing brackets

Strut (if included)

Track rollers

Keys

(as required)

RH/LH (as required)

WARNING WARNING

PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, ENSURE YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTALLATION INSTRUCTIONS. OTHERWISE, THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY.

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

LOOKING OUT.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To ﬁnd your local Wayne-Dalton dealer,

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

Strut clips

Pull rope

(if included)

Inside/ Outside

Step Plates

3/8”-16 x 1-1/2” Hex bolts (as required)

Lift Handles

Center coupler

assembly (as required)

Weather seals & nails (If included)

(as required)

Warning labels

1/4”-20 x 5/8” Self

drilling screws (as required)

1/4”- 20 Flanged

hex nuts (as required)

1/4”-14 x 5/8”

Tamper resistant Self

drilling screws (as required)

1/4”-20 x 7/8” Self

drilling screws (as required)

(2) 3/8”- 16 Hex nuts

5/16”- 18 x 1/2”

Carriage bolts (as required)

5/16” x 2” Tamper-resistant hex head

5/16” x 2” Hex head lag screws

3/8”-16 x 3/4” Hex bolts

Carriage bolts (as required)

1/4”x 2-1/2” Carriage bolts

lag screw (as required)

(as required)

5/16”- 18 Flange

hex nuts (as required)

1/4”-20 x 5/8”

(as required)

Door Section Identiﬁcation

Door Section Identiﬁcation (8300-8500)

Door Height Bottom Lock (second)

6’0” 3-Sec 24” 24” N/A N/A 24”

6’0” 4-Sec 18” 18” 18” N/A 18”

6’3” 4-Sec 21” 18” 18” N/A 18”

6’6” 4-Sec 21” 18” 18” N/A 21”

6’9” 4-Sec 21” 21” 18” N/A 21”

7’0” 4-Sec 21” 21” 21” N/A 21”

7’3” 4-Sec 24” 21” 21” N/A 21”

7’3” 4-Sec 21” 21” 21” N/A 24”

7’6” 4-Sec 24” 21” 21” N/A 24”

7’6” 5-Sec 18” 18” 18” 18” 18”

7’9” 4-Sec 24” 24” 24” N/A 18”

7’9” 4-Sec 24” 24” 21” N/A 24”

7’9” 5-Sec 21” 18” 18” 18” 18”

8’0” 4-Sec 24” 24” 24” N/A 24”

8’0” 5-Sec 21” 18” 18” 18” 21”

Intermediate I

(third)

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 ﬁve sections in height, you will not receive an Intermediate II 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.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To ﬁnd your local Wayne-Dalton dealer,

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

Intermediate II

(fourth)

Top

Bottom weather seal

Intermediate I section

Bottom corner bracket warning labels

Bottom section

Section

height

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.

WARNING WARNING

A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS, RELEASE THE SPRING TENSION.

For detailed information see supplemental instructions “Removing an Existing Door/ Preparing the Opening”. These instructions are 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 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.

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

BACKROOM REQUIREMENTS

Door Height Track Manual Lift Motor Operated

6’0” to 7’0” 12”, 14” Radius 102” (2591 mm) 125” (3175 mm)

7’1” to 8’0” 12”, 14” Radius 114” (2896 mm) 137” (3480 mm)

HEADROOM REQUIREMENTS

Track Type Space Needed

12” Radius 13-1/2” (343 mm)

14” Radius 14 1/2” (368 mm)

Suitable mounting surface 2”x 6” lumber minimum

Header board 2”x 6” lumber preferred

Headroom

Min. Side 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

Fully Adjustable track

Jamb

Nail

1/8” to 1/4”

Weatherstrips

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To ﬁnd your local Wayne-Dalton dealer,

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

INSTALLATION

1st hole set

2nd hole set 3rd hole set

Top of track

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.

Vertical Tracks

NOTE: If you have a wall angle track assembly, skip this step. NOTE: Refer to Door Section Identiﬁcation / Parts Breakdown, to determine if you have verti-

cal tracks. Vertical tracks may or may not have to be cut to the proper length, prior to installing. IMPORTANT: VERTICAL TRACKS ARE NOT REQUIRED TO BE CUT DOWN IF YOU HAVE DOOR

HEIGHTS 7’-0” OR 8’-0”. Determine the radius of your horizontal track.

Refer to the vertical track cutting chart to determine the length needed to be cut off at the top of the vertical tracks. Using this measurement, measure and cut the vertical track off at the top, as shown. Remove any burrs from the cut edge of vertical track.

Tools: Power Drill, 5/16” Drill Bit, Hacksaw, Tape Measure

12”

Stamped

radius

Vertical Track Cutting Chart

Horizontal Track Radius Vertical Track Cut Length

10” Or 12” Radius Door Height Minus 10”

14” Radius Door Height Minus 8”

Measure and cut

Horizontal

track

Slot pattern

1/4”- 20

Flange hex nut

Jamb

bracket

1/4”- 20 x 5/8”

Carriage bolt

Vertical track

Jamb bracket

in place

Flag Angles

NOTE: If you have a wall angle track assembly, skip this step. Refer to Package Contents /

Parts Breakdown, to determine if you have ﬂag angles. NOTE: Flag angles are right and left handed. Hand tighten the left hand ﬂag angle to the left hand vertical track using (2) 1/4”-20 x 5/8”

carriage 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.

Tools: None

(2) 1/4”-20

Flange hex nuts

Flag angle

Vertical

track

(2) 1/4”- 20 x 5/8”

Carriage bolts

5/8”

Top of

track

1/2”

Vertical

track

Now, two holes must be drilled into the top of the cut vertical track. Using the illustration shown below, mark and drill the hole locations using a 5/16” drill bit. Once the holes have been drilled, remove any burrs from the drilled holes. Repeat the same process for the other vertical track.

5/8”

Measure and drill

5/16” Holes

Vertical

track

Attaching Jamb Brackets

NOTE: If you have a wall angle track assembly, skip this step. Refer to Package Contents /

Parts Breakdown, to determine if you have ﬂag angles. NOTE: The bottom jamb bracket is always the shortest bracket or the lowest number marked

on the jamb bracket. The center jamb bracket is the next tallest or the next higher number marked on the jamb bracket. If three jamb brackets per side are included with your door, you will have received a top jamb bracket, which is the tallest or the highest number marked on the jamb bracket.

To attach the bottom jamb bracket, locate lower slot pattern of the 1st hole set on the vertical track. Align the slot in the jamb bracket with the lower slot pattern. Loosely, secure jamb bracket using (1) 1/4”-20 x 5/8” carriage bolt and (1) 1/4”-20 ﬂange hex nut. Repeat for other side.

Place the center jamb bracket over the slot pattern that is centered between the bottom jamb bracket and ﬂag angle of the 2nd hole set. Loosely, secure jamb bracket using (1) 1/4”-20 x 5/8” carriage bolt and (1) 1/4”-20 ﬂange hex nut. Repeat for other side.

If a top jamb bracket was included, loosely secure it to vertical track using the slot pattern in the 3rd hole set and (1) 1/4”-20 x 5/8” carriage bolt and (1) 1/4”-20 ﬂange hex nut. Repeat the same process for the other vertical track.

Tools: None

Bottom Corner Brackets

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this

manual or refer to Parts Breakdown on page 2. NOTE: Bottom corner brackets are right and left handed.

Tools: Power drill, 7/16” Socket driver, 1/4” Torx bit

WARNING WARNING

FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER COTTER PIN COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN, ALLOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR FATAL INJURY.

Uncoil the counterbalance lift cables. Place the left hand cable loop into position between the two holes on the side of the left hand bottom corner bracket. Slide a clevis pin through the innermost hole, cable loop, and outermost hole, of the bottom corner bracket. Secure in place by inserting a cotter pin into the hole of the clevis pin. Bend the ends of the cotter pin outwards to secure it in place. Attach 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, with the appropriate 1/4”-20 x 7/8” self drilling screws and (1) 1/4”-14 x 5/8” tamper resistant self drilling screw. Insert a short stem track roller into the left hand bottom corner bracket. Repeat for the right hand side.

NOTE: Verify bottom weather seal is aligned with bottom section. If there is more than 1/2” excess weather seal on either side, trim weather seal even with bottom section.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To ﬁnd your local Wayne-Dalton dealer,

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

+ 14 hidden pages