Wayne-Dalton 8000 Series Quick start guide

8000 Series, Model 46
IMPORTANT NOTICE!
Read these instructions carefully before
attempting installation. If in question about
any of the procedures, do not perform the
work. Instead, have a qualified door agency
do the installation or repairs.
© Copyright 2009 Wayne-Dalton Corp. Part No. 327691 REV2 08/03/2009
Extension Spring
Installation Instructions and Owner’s Manual
Portland Source Plant

2
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
READ THESE INSTRUCTIONS
CAREFULLY BEFORE ATTEMPTING
INSTALLATION. IF IN QUESTION
ABOUT ANY OF THE PROCEDURES, DO
NOT PERFORM THE WORK. INSTEAD,
HAVE A QUALIFIED DOOR AGENCY DO
THE INSTALLATION OR REPAIRS.
1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.
2. Wear protective gloves during installation to avoid possible
cuts from sharp metal edges.
3. It is always recommended to wear eye protection when using
tools, otherwise eye injury could result.
4. Avoid installing your new door on windy days. Door could
fall during the installation causing severe or fatal injury.
5. Doors 12’- 0” wide and wider should be installed by two
persons, to avoid possible injury.
6. Operate door ONLY when it is properly adjusted and free from
obstructions.
7. If a door becomes hard to operate, inoperative or is damaged,
immediately have necessary adjustments and/or repairs
made by a trained door system technician using proper tools
and instructions.
8. DO NOT stand or walk under a moving door, or permit
anybody to stand or walk under an electrically operated door.
9. DO NOT place fingers or hands into open section joints when
closing a door. Use lift handles/gripping points when operating
door manually.
10. DO NOT permit children to operate garage door or door
controls. Severe or fatal injury could result, should the child
become entrapped between the door and the floor.
11. Due to constant extreme spring tension, DO NOT attempt any
adjustment, repair or alteration to any part of the door,
especially to springs, spring brackets, bottom corner brackets,
red colored fasteners, cables or supports. To avoid possible
severe or fatal injury, have any such work performed
by a trained door systems technician using proper tools and
instructions.
12. On electrically operated doors, pull down ropes must be
removed and locks must be removed or made inoperative in
the open (unlocked) position.
13. Top section of door may need to be reinforced when attaching
an electric opener. Check door and/or opener manufacturer’s
instructions.
14. VISUALLY inspect door and hardware monthly for worn and or
broken parts. Check to ensure door operates freely.
15. Test electric opener’s safety features monthly, following
opener manufacturer’s instructions.
16. NEVER hang tools, bicycles, hoses, clothing or anything else
from horizontal tracks. Track systems are not intended or
designed to support extra weight.
After installation is complete, fasten this manual
near garage door.
Table of Contents
Important Safety Instructions ............................................ 2
Package Contents..........................................................3-4
Door Section Identification ................................................ 4
Tools Required.................................................................. 5
Pre-Installation ............................................................5-10
Removing The Old Door .................................5-9
Preparing The Opening ................................... 10
Installation ................................................................11-27
Optional Installations .................................................28-29
Side Lock ....................................................... 28
Pull Rope........................................................ 28
Trolley Operator .............................................. 29
Maintenance................................................................... 30
Cleaning......................................................... 30
Painting Instructions ....................................... 30
Warranty......................................................................... 31
Dealer Locator Information.............................................. 32
Definition of key words used in this manual:
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.
WARNING
WARNING

3
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Package Contents
(2) HORIZONTAL TRACKS RH/LH
NOTE: DEPENDING ON THE DOOR MODEL, SOME PARTS
LISTED WILL NOT BE SUPPLIED IF NOT NECESSARY. REAR
SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR.
DOOR SECTIONS (AS REQUIRED)
(2) STEP PLATES
FULLY ADJUSTABLE JAMB
BRACKETS (AS REQUIRED)
(2) ROLLER SPACERS
MANUAL
WEATHER SEAL &
NAILS (IF INCLUDED)
#1, #2, #3, & #4 HINGES
(AS REQUIRED)
(2) TOP BRACKET
BASES
(2) TOP BRACKET
SLIDES
#6 SCREW EYE AND PULL
ROPE (IF INCLUDED)
(2) EXTENSION
SPRINGS
(2) FULLY ADJUSTABLE
RH/LH FLAGANGLES
(2) LIFT HANDLES
& SPACERS
RIGHT AND LEFT
BOTTOM BRACKETS
ROLLERS
(AS REQUIRED)
(2) SHEAVE FORKS
(2) SNUBBER CABLES
U-BAR
(AS REQUIRED)
5/16”-18 X 3-3/4”EYE
HOOKS (AS REQUIRED)
(2) FRONT SHEAVES
S-HOOKS
(AS REQUIRED)
(2) COUNTERBALANCE
CABLES
3 HOLE CLIPS
(AS REQUIRED)
(2) REAR SHEAVES
8000 Series, Model 46
IMPORTA NT NOTICE!
Read these instructions carefully before
attemptinginstallation. If in question about
anyof the procedures, do not perform the
work.I nstead, hav e a qualified doo r agency
dothe installation or r epairs.
©Copyright 2002-2006 Wayne-Dalton Corp. Part No. 300663 Rev208/31/2006
Extension Spring
InstallationInstructions and Owner’s Manual
PortlandSource Plant
(2) VERTICAL
RH/LH TRACKS
(2) HOOK PLATES
(IF INCLUDED)

4
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Tools Needed:
1/4”- 20 X 5/8” CARRIAGE
BOLTS (AS REQUIRED)
The BOTTOM SECTION can be
identified by the factory attached
bottom astragal, or by the bottom
bracket warning labels on each end
stile. This section is always the 1st
section on four and five section doors.
The LOCK SECTION may have a yellow
and black warning label on the right
side of the section. This section is
always the 2nd section on four and five
section doors.
The INTERMEDIATE I SECTION may
have a warning label attached to either
right or left hand endstile of the section.
This section is always the 3rd section
from the bottom of the door.
The INTERMEDIATE II SECTION is
always the 4th section on five section
door.
The TOP SECTION is always the 4th
section on four section door and the 5th
section on five section door.
Door Section Identification
5/16” X 2” HEX LAGS (AS REQUIRED)
3/8”- 16 HEX
NUTS (AS REQUIRED)
1/4”- 20 FLANGE HEX
NUTS (AS REQUIRED)
1/4”- 14 X 5/8” SELF TAPPING
SCREWS (AS REQUIRED)
(4) 1/4”- 20 HEX
NUTS
(2) 1/4”- 20 X 5/8” TAMPER
RESISTANT SCREWS 1/4”- 20 X 7/8” SELF DRILLING
SCREWS (AS REQUIRED)
1/4”- 20 X 11/16” SELF DRILLING
SCREWS (AS REQUIRED)
(2) 1/4” X 2- 1/2” CARRIAGE BOLTS
Package Contents Continued...
3/8”- 16 X 1-1/4” HEX HEAD
BOLTS (AS REQUIRED)
TOP SECTION
INTERMEDIATE II SECTION (5 SECTION DOORS ONLY)
LOCK SECTION
BOTTOM SECTION
BOTTOM BRACKET
WARNING LABELS
ASTRAGAL
WARNING LABEL
(2) 1/4” X 2-3/4” CARRIAGE BOLTS
INTERMEDIATE I SECTION
5/16”- 18 HEX NUTS
(AS REQUIRED)
3/8”- 16 X 3/4” HEX HEAD BOLTS
(AS REQUIRED)

5
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
PRE-INSTALLATIONPRE-INSTALLATION
Tools Required
Removing An Old Door
SAFETY GLASSES
FLAT TIP SCREWDRIVER
1/4”, 3/8”, 7/16” & 9/16”
WRENCHES
7/16” & 9/16”
SOCKET
PHILLIPS HEAD
SCREWDRIVER
RATCHET WRENCH
POWER DRILL
SAWHORSE
GLOVES
3/8”, 7/16” SOCKET
DRIVER
HAMMER
VICE GRIPS
STEP LADDER
TAPE MEASURELEVEL VICE CLAMPS
PENCIL
9/32”, 1/2”, 3/16” & 1/8”
DRILL BITS
IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED, DO NOT ATTEMPT TO WORK ON IT, BUT
HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO
PREVENT UNINTENDED DOOR OPERATION. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL
SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.
IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT REMOVING DOOR, OR SEVERE INJURY COULD RESULT
REMOVING AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSTRUCTIONS ON PAGES 6-10 “REMOVING AN
OLD DOOR/PREPARING THE OPENING” CAREFULLY, OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
If you have an existing door, follow the instructions to identify which counterbalance removal is necessary. The process of removing
an existing door begins by identifying it’s counterbalance system. If you are not removing an existing door, proceed to PREPARING THE
OPENING on page 10. Generally, you will find three (3) types of counterbalance systems: Extension Spring, Wayne-Dalton®exclusive
TorqueMaster®and Torsion counterbalance system, see pages 6-9.
For more technical information regarding the opening preparation, installation and use of your garage door and opener, you can go to
www.dasma.com and click on Publications and then Technical Data Sheet.
WARNING
WARNING
WARNING
WARNING
WARNING

6
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Tools Needed:
FAILURE TO USE APPROVED
WINDING BARS CAN CAUSE SPRING
ENERGY TO BE RELEASED
SUDDENLY, RESULTING IN SEVERE
OR FATAL INJURY.
COUNTERBALANCE SPRING
TENSION MUST BE RELIEVED
BEFORE REMOVING ANY
HARDWARE. A POWERFUL SPRING
RELEASING IT’S ENERGY SUDDENLY
CAN CAUSE SEVERE OR FATAL
INJURY.
Do not release the torsion spring
tension unless you are a qualified and
experienced door technician. Instead have
a professional door agency release the
tension.
Step 1: Close the door and place vice
clamps on the back legs of both vertical
tracks, above the third roller to prevent the
door from lifting as you unwind the springs.
Use only approved winding bars available
from your dealer. Do not use undersized
steel rods, screw drivers or anything else
to unwind the springs. Position the ladder
just off to the side of the winding cone.
The winding cone should be easy to reach
without putting your body directly in front
of it.
Step 2: Insert a winding bar into one of the
holes in the winding cone. Exert upward
pressure. Using caution, loosen the two
(2) set screws in the winding cone. Be
prepared to support the full torsional force
of the spring when the set screws are
loosened.
Step 3: Once set screws are loose, slowly
and carefully lower the winding bar until it
rests against the door. Insert other winding
bar into the upper hole. Push up and
remove lower bar. Carefully lower upper
winding bar, until it contacts the door.
Repeat process, 1/4 turns at a time until all
tension is relieved. If your door is equipped
with two (2) torsion springs, follow the
same procedure to relieve tension on the
second spring.
Step 4: Remove vice clamps from tracks,
unbolt torsion shaft assembly and remove
from work area.
NOTE: Continue with “P4” on page 9 after
completing this step.
WARNING
WARNING
APPROVED WINDING BAR
TORSION SPRING ASSEMBLY
WINDING CONE
SET SCREWS
FIRMLY HOLD WINDING BARS AND
CAUTIOUSLY LOOSEN SET SCREWS
P1
Recommended
tools from
page 5
Torsion Spring Removal
For Standard Lift

7
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
PRE-INSTALLATION
Tools Needed:
Fig. 2
Fig. 1
Fig. 3
Fig. 4
RIGHT HAND
CABLE DRUM
TORQUEMASTER®
SPRING TUBE
CHECK CABLE
TENSION
COUNTER
GEAR/ COVER
RIGHT HAND
END BRACKET
PLACE MARK ON END BRACKET
AND DRIVE GEAR TOOTH
BEFORE UNWINDING SPRINGS
END BRACKET
RIGHT HAND
WINDING BOLT HEAD
ELECTRIC DRILL
WITH 7/16” HEX
DRIVER (DO NOT
USE IMPACT
GUN)
PRY COUNTER GEAR
AND COUNTER COVER
FROM END BRACKET
USING FLAT TIP
SCREWDRIVER
COUNTER
GEAR
COUNTER
COVER
TorqueMaster®Spring Removal
P2
Recommended
tools from
page 5
A TorqueMaster®spring system can be
identified by the end brackets. For single
spring applications, the right hand end
bracket will always have a drive gear,
counter gear, counter cover, and a winding
bolt head. The left hand end bracket will
have no gears, counter cover, or winding
bolt head. The hole for the winding bolt
head will be plugged.
For double springs, both the right hand
and left hand end brackets will always
have a drive gear, counter gear, counter
cover and a winding bolt head.
IMPORTANT: RIGHT AND LEFT HAND IS
ALWAYS DETERMINED FROM INSIDE THE
BUILDING LOOKING OUT.
Step 1: If you have a black counter cover:
Place a mark on the drive gear tooth and an
adjacent mark on the right hand end bracket
(Fig. 1). Loosen the lock nut using a 7/16”
wrench and continue with step 2.
If you have a gray counter cover: Loosen
the lock nut using a 7/16” wrench and
continue with step 2.
Step 2: Using an electric drill (High
torque / gear reduced to 1300 rpm
preferred) with a 7/16” hex head driver,
unwind the right hand winding bolt head
counterclockwise (Fig. 2) and count the
number of turns the mark on the drive
gear passes the adjacent mark on the end
bracket. Referencing the chart below, by
door height, stop unwinding the spring
once the counted turns have reached the
listed number of turns.
6’- 0” Door Height = 14 turns
6’- 3” Door Height = 14 1/2 turns
6’- 5” Door Height = 15 turns
6’- 6” Door Height = 15 turns
6’- 8” Door Height = 15 1/2 turns
6’- 9” Door Height = 15 1/2 turns
7’- 0” Door Height = 16 turns
7’- 3” Door Height = 16 1/2 turns
7’- 6” Door Height = 17 turns
7’- 9” Door Height = 17 1/2 turns
8’- 0” Door Height = 18 turns
CAUTION: DO NOT USE IMPACT GUN TO
UNWIND SPRINGS.
IMPORTANT: DO NOT REFERENCE THE
COUNTER COVER WHEN COUNTING THE
NUMBER OF TURNS BEING UNWOUND
ON THE SPRING, BUT FOLLOW THE
INSTRUCTIONS ABOVE.
Step 3: Verify that spring tension has been
released by pulling the counterbalance
cable on the right hand cable drum away
from the header (Fig. 3). If spring tension
has been released, the cable will be loose.
In addition, the TorqueMaster®Spring
Tube should be free to rotate in either
direction.
LOOSEN LOCK
NUT

8
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Tools Needed:
Fig. 5
Fig. 9
REMOVE TOP
LAG SCREW
REMOVE CABLE DRUM AND
WINDING SHAFT
DRAPE CABLE ACROSS
TOP OF FLAGANGLE
LIFT
TORQUEMASTER®
SPRING TUBE
OFF FLAGANGLE
TorqueMaster®Spring
Removal continued...
Recommended
tools from
page 5
Fig. 8
CENTER
BRACKET
ASSEMBLY
(2) 5/16” X 1-5/8”
HEX HEAD LAG
SCREWS
Fig. 7
PRY END BRACKET FROM WINDING
SHAFT USING A FLAT TIP SCREW
DRIVER AND LOCKING PLIERS
HOLD THE
END BRACKET
STEADY WITH
LOCKING PLIERS
Fig. 6
REMOVE
BOTTOM LAG
SCREW
USE LOCKING PLIERS
TO HOLD END BRACKET
REMOVE #10
PHILLIPS HEAD
SCREW
If the counterbalance cable is still taut and
the TorqueMaster®spring tube is difficult
to rotate, that is an indication that spring
tension still exists on the left hand spring.
Repeat Steps 1 and 2 for releasing spring
tension on the left hand side.
Step 4: Using a flat tip screwdriver, pry
the counter gear and counter cover
from the right hand end bracket (Fig. 4
on previous page). Discard the counter
gear and counter cover. On double spring
applications, repeat for left hand side.
Step 5: Remove the upper
5/16” x 1-5/8” lag screw from the right
hand end bracket (Fig. 5). Attach locking
pliers to the upper portion of the end
bracket and hold the housing steady while
removing the lower 5/16” x 1-5/8” lag
screw and #10 x 1/2” phillips head screw
from the end bracket (Fig. 6).
Step 6: Holding the right hand end
bracket steady with locking pliers,
carefully pry the end bracket and drive
gear off the winding shaft using a flat tip
screwdriver (Fig. 7).
CAUTION: THE WINDING SHAFT MAY
ROTATE WHEN REMOVING THE END
BRACKET AND DRIVE GEAR.
Step 7: Repeat Step 4 for the left hand
side. Holding the left hand end bracket
steady with locking pliers, carefully pry
the end bracket off the winding shaft
using a flat tip screwdriver (Fig. 7).
Step 8: Remove the two (2) lag bolts
attaching the center bracket assembly to
the header board (Fig. 8).
Step 9: Lift the right hand side of the
TorqueMaster®Spring Tube and slide the
cable drum off. Realign the groove in the
winding shaft with the round notch in the
flagangle and drape the counterbalance
cable with drum over the flagangle. Lift
the left hand side of the TorqueMaster®
Spring Tube and slide the cable drum
and winding shaft off (Fig. 9). Drape the
counterbalance cable with drum over the
flagangle. Lift the TorqueMaster®spring
assembly off the flagangles and out of
the doorway. Unhook the counterbalance
cables from the bottom brackets and
remove all parts from the work area.
NOTE: The cable drums may be difficult to
remove. If so, twist the cable drum to aid
in removal.
NOTE: Continue with “P4” on page 9 after
completing this step.

9
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Tools Needed:
Tools Needed:
PRE-INSTALLATION
Step 1: Raise the door to the fully open
position and place vice clamps to the back
legs of both vertical tracks, below the
bottom rollers to prevent the door from
falling. By opening the door you release
most of the spring tension. Carefully
unfasten the S-hook from the horizontal
angle. Remove cable, sheave and extension
spring. Repeat for the other side. If safety
cables are running through the extension
springs, remove them also. Remove parts
from work area.
Step 2: Holding door in the open position,
remove the vice clamps, be prepared
to support the entire weight of the door.
Garage doors can weigh 200-400 pounds.
With assistance, carefully lower the door, by
grasping the door firmly by it’s lift handles.
Do not place fingers or hands near joints,
between sections, or between bottom of
door and floor. Otherwise, severe injury
could result.
NOTE: Continue with “P4” on page 9 after
completing this step.
Extension Spring Removal
BOTTOM SECTION
(DOOR OPEN)
CAREFULLY REMOVE “S”
HOOK AND COUNTERBALANCE
CABLE (REPEAT FOR THE
OPPOSITE SIDE)
HORIZONTAL ANGLE
REMOVE LAG SCREW
FROM SAFETY CABLE (IF
INSTALLED). REPEAT FOR
OPPOSITE SIDE.
P3
Recommended
tools from
page 5
Removing the Old Door
TOP BRACKET
HINGES
HORIZONTAL TRACK
P4
Recommended
tools from
page 5
Having removed the counterbalance
system, the door can now be
disassembled.
Start by first removing the top row of
hinges.
With assistance, hold the top section to
keep it from falling and remove the
top brackets. With assistance, lift the top
section out of the opening and remove
it from the work area. Repeat for all
remaining sections.
After door is disassembled, unbolt both
track assemblies from the jambs and
remove all material from the work area.
You can neatly dispose of the old door by
placing it in the carton of your new door.
Clean up area and complete “Preparing
the Opening” “P5” on page 10 before
installing the new door.

10
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Tools Needed: FAILURE TO
SECURELY ATTACH A SUITABLE MOUNTING
PAD TO STRUCTURALLY SOUND FRAMING
COULD CAUSE SPRINGS TO VIOLENTLY PULL
MOUNTING PAD FROM WALL, RESULTING IN
SEVERE OR FATAL INJURY.
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 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 Extension spring applications. For low headroom applications, the jambs
should extend to the ceiling height. Minimum side clearance required, from
the opening to the wall, is 3-1/2” (89 mm).
IMPORTANT: Closely inspect jambs and header material. Any wood found
not to be sound, must be replaced.
Weather Seal (May Not Be Included):
Cut or trim the weather seal (if necessary) to the header and jambs.
For quick install track: Align the header seal with the inside edge of the
header and temporarily secure it to the header with equally spaced nails.
Next, fit the jamb seals up tight against the header seal and flush with the
inside edge of the jamb.Temporarily secure the jamb seals with equally
spaced nails. This will keep the bottom section from falling out of the
opening during installation.
For fully adjustable track: Align the header seal 1/8” to 1/4” inside the
header and temporarily secure it to the header with equally spaced nails.
Next, fit the jamb seals up tight against the header seal and 1/8” to 1/4”
inside the jamb. Temporarily secure the jamb seals with equally space nails
approximately 12” to 18” apart.This will keep the bottom section from
falling out of the opening during installation.
NOTE: Do not permanently attach weather seal to the jamb at this time.
HEADROOM REQUIREMENT: Headroom is defined as the space needed
above the top of the door for tracks, springs, etc. to allow the door to open
properly. If the door is to be motor operated, 2-1/2” (64 mm) of additional
headroom is required.
NOTE: 6” LHR Conversion Kit is available for 12” Radius only. Contact your
local 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.
Preparing the Opening
WEATHER SEAL
HEADROOM
BACKROOM
DOOR
WIDTH
DOOR HEIGHT
LEVEL HEADER
PLUMB JAMBS
HEADER BOARD
2” X 6” LUMBER
PREFERRED
SUITABLE MOUNTING
SURFACE 2” X 6”
LUMBER MINIMUM
P5
Recommended
tools from
page 5
HEADER
JAMB
JAMB
JAMB
WEATHER
SEAL
HEADROOM
REQUIREMENT
DOOR
HEIGHT TRACK MANUAL
LIFT
MOTOR
OPERATED
6’5” 10”, 12”, 14” Radius 89” 120”
6’5” Low Headroom 101” 120”
6’6” 10”, 12”, 14” Radius 90” 120”
6’6” Low Headroom 102” 120”
7’0” 10”, 12”, 14” Radius 96” 120”
7’0” Low Headroom 108” 120”
7’6” 10”, 12”, 14” Radius 102” 132”
7’6” Low Headroom 114” 132”
8’0” 10”, 12”, 14” Radius 108” 132”
8’0” Low Headroom 120” 132”
BACKROOM REQUIREMENT
TRACK TYPE Extension
10”, 12” 10”
14” 12”
LHR Kit 6 1/2”
WARNING

11
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Tools Needed:
INSTALLATION
Installation
1
IMPORTANT: READ INSTRUCTIONS TITLED “P4” “REMOVING THE OLD DOOR” ON PAGE 9 AND “P5” “PREPARING THE OPENING” ON
PAGE 10 BEFORE ATTEMPTING DOOR INSTALLATION.
IMPORTANT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS,
END BRACKETS, JAMB BRACKETS, OPERATOR MOUNTING/SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER
(PRESERVATIVE-TREATED). STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UNTREATED
LUMBER.
NOTE: It is recommended that 5/16” x 2” lag screws be pilot drilled using a 3/16” drill bit, and 1/4” x 2” lag screws and 1/4” x 1-1/2”
lag screws be pilot drilled using a 1/8” drill bit, prior to fastening.
Attaching Fully Adjustable
Flagangle to Vertical Track
None
NOTE: If you have riveted track, skip
this step.
Hand tighten the flagangle to the
vertical track using (2) 1/4”- 20 x 5/8”
carriage bolts and (2) 1/4”- 20 flange
hex nuts. Secure the flange nuts after
flagangle spacing is complete (Step 12).
(2) 1/4”- 20 X 5/8”
CARRIAGE BOLTS
(2) 1/4”- 20
FLANGE HEX NUTS
FULLY
ADJUSTABLE
FLAGANGLE
VERTICAL
TRACK

12
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Tools Needed:
2
None
Installing Fully Adjustable Jamb
Brackets
1ST SET
3RD SET
FULLY ADJUSTABLE
JAMB BRACKET
JAMB BRACKET SLOT
(1) 1/4”- 20 X 5/8”
CARRIAGE BOLT
(1) 1/4”- 20
FLANGE
HEX NUT
JAMB BRACKET
VERTICAL
TRACK
QUICK INSTALL
FEATURE
QUICK INSTALL
FEATURE
VERTICAL
TRACK
NOTE: If you have riveted track, skip
this step.
To attach the bottom jamb bracket,
JB-2, locate the first set of quick install
features of the vertical track. Align
the slot in the jamb bracket with the
slot above the quick install features in
the vertical track. The long side of the
bracket is placed against the track.
Fasten the jamb bracket finger tight,
using (1) 1/4”- 20 x 5/8” carriage bolt
and (1) 1/4”- 20 flange hex nut.
To attach the top jamb bracket, JB-3,
locate the third set of quick install
features of the vertical track. Align
the slot in the jamb bracket with the
slot above the quick install features in
the vertical track. The long side of the
bracket is placed against the track.
Fasten the jamb bracket finger tight,
using (1) 1/4”- 20 x 5/8” carriage bolt
and (1) 1/4”- 20 flange hex nut.

13
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Tools Needed:
Tools Needed:
INSTALLATION
4Counterbalance Cables
IMPORTANT: RIGHT AND LEFT HAND IS
ALWAYS DETERMINED FROM INSIDE THE
GARAGE LOOKING OUT.
NOTE: For door section identification see
page 4.
Uncoil the counterbalance cables and
slip the loop at the ends of the cables
over each milford pin on the bottom
section.
Insert a roller with a space into bottom
bracket of the bottom section.
Repeat for other side.
NOTE: Verify astragal (bottom seal)
is aligned with door section. If there
is more than 1/2” excess astragal on
either side, trim astragal even with door
section.
BOTTOM SECTION
MILFORD PIN
ROLLERS
HINGE TUBE
BOTTOM
BRACKET
BOTTOM SECTION
ASTRAGAL
None
Align center hole of bottom bracket
with hole #3 hole in end stile of bottom
section. Fasten with
(2) 1/4”- 20 x 11/16” self drilling
screws and (1) 1/4”- 20 x 5/8”
tamper-resistant self drilling screw as
shown.
NOTE: Only doors provided to
professional installers, who have
required tools will be supplied with a
tamper-resistant fastener. Use
(1) 1/4”- 20 x 11/16” self drilling screw
in bottom bracket, if not provided with a
tamper-resistant screw.
NOTE: Bottom section can be identified
by the factory attached bottom astragal
and by the bottom bracket warning
labels on each end stile.
3Bottom Bracket
1
2
3
4
5
6
7
7
6
5
4
3
2
1
BOTTOM BRACKET
BOTTOM
BRACKET
(2) 1/4”- 20 X 11/16”
SELF DRILLING
SCREWS
(1) 1/4”- 20 X 5/8”
TAMPER-RESISTANT
SELF DRILLING
SCREW
BOTTOM
BRACKET
BOTTOM
SECTION
Power Drill
7/16” Socket
Driver
WARNING
LABEL
END STILE HOLE
PATTERN
(LEFT SIDE IS SHOWN.
RIGHT SIDE IS
OPPOSITE.)
ROLLER SPACER
COUNTERBALANCE CABLE

14
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Tools Needed: NOTE: For door section identification see
page 4.
Located the bottom section, (2) #1
hinges for the end stiles and enough #1
hinge(s) for each of the center stile(s).
Place the hinge on the section so that
the lower (numbered) leaf of the hinge
is over the pre-punched holes in the end
stiles and center stile(s) at the top of the
section.
Secure the hinges to the section using
(2) 1/4”- 14 x 5/8” self tapping screws
each.
Insert roller into appropriate end hinge
tube.
Repeat for all sections except the top
section.
Use (2) #2 end hinge(s) and the required
number of #1 hinges for each of the
center stile(s) on the lock section
(second section).
Use (2) #3 end hinges and the required
number of #1 hinges for each of the
center stile(s) on the intermediate
section (third section).
If installing a five section door, use (2) #4
end hinges and the required number of
#1 hinges for each of the center stile(s)
on the intermediate II section (fourth
section).
IMPORTANT: WHEN PLACING ROLLERS
INTO END HINGES NUMBER 2 AND
HIGHER, THE ROLLER GOES INTO TUBE
FURTHEST AWAY FROM SECTION.
IMPORTANT: ONCE FASTENER IS
SNUG AGAINST HINGE LEAF, TIGHTEN
AN ADDITIONAL 1/4 TO 1/2 TURN TO
RECEIVE MAXIMUM DESIGN HOLDING
POWER.
5Hinges
Power Drill
7/16” Socket
Driver
END STILE HOLE
PATTERN
(LEFT SIDE IS SHOWN.
RIGHT SIDE IS
OPPOSITE.)
1
2
3
4
5
6
7
7
6
5
4
3
2
1
#1 HINGE #2 END HINGE
#3 END HINGE #4 END HINGE
CENTER STILE
HOLE PATTERN
ROLLER
PLACEMENT
ROLLER
PLACEMENT
ROLLER
PLACEMENT
HINGE
(2) 1/4”- 14 X 5/8”
SELF TAPPING
SCREWS
CENTER STILE
(2) 1/4”- 14 X 5/8”
SELF TAPPING
SCREWS
HINGE
END STILE
END HINGE PLACEMENT
CENTER HINGE PLACEMENT

15
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Tools Needed:
INSTALLATION
6Top Bracket
Power Drill
7/16” Socket
Driver
Align upper-center hole of top bracket
with #6 hole in the end stile (See End
Stile Hole Pattern on page 14). Ensure
top bracket is level and aligned with
edge of section. Secure with
(2) 1/4”- 20 x 11/16” self drilling
screws, one in each top corner of the
top bracket.
Ensure top bracket is level and aligned
with edge of section. Secure with
(2) 1/4”- 20 x 11/16” self drilling
screws, one in each bottom corner of
the top bracket.
Loosely fasten top bracket slide with
(1) 1/4”- 20 x 5/8” carriage bolt and
(1) 1/4” x 20 flange hex nut. Insert roller.
Repeat for other side.
NOTE: For doors with a glazed top
section (windows). Top strut may be
mounted between #2 and #6 holes
before top bracket is installed. See
Step 8 for U-Bar installation
(4) 1/4”- 20 X 11/16”
SELF DRILLING SCREW
TOP BRACKET
BASE
END STILE
TOP SECTION
TOP SECTION
TOP
BRACKET
BASE
TOP SECTION
TOP
BRACKET
ASSEMBLY
1/4” X 20
FLANGE HEX
NUT
1/4”- 20 X 5/8”
CARRIAGE BOLT
TOP
BRACKET
SLIDE
#6 HOLE
CENTER HOLE

16
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Tools Needed:
7Step Plate
Locate the center most stile of the
bottom section of the door.
On the inside of the door, center the
step plate/lift handle on the center
most stile no higher than 6” from the
bottom of the door. Using the step
plate/lift handle holes as a guide, drill a
5/16” dia. hole along each side of the
stile through the face of the door. (Drill
through insulation and door’s face on an
insulated door.) Be extremely careful to
keep drill straight.
Mount step plates/ lift handles back to
back, straddling stile. Secure with (2)
1/4” x 2-3/4” carriage bolts and
1/4”-20 hex nuts.
STEP PLATE
ASSEMBLY
BOTTOM
SECTION
INSIDE STEP PLATE INSTALLATION
OUTSIDE STEP PLATE INSTALLATION
(2) 1/4” X 2-3/4”
CARRIAGE BOLTS
STEP PLATE
BOTTOM
SECTION
DRILL (2) 5/16” DIA.
HOLES THROUGH
DOOR FACE
ASTRAGAL
6” MAX
MOUNTING
HEIGHT
STEP PLATE
INSIDE STEP PLATE INSTALLATION
BOTTOM
SECTION
CENTER MOST STILE
6” MAX
MOUNTING
HEIGHT
Tape Measure
Pencil
5/16” Drill Bit
Power Drill
7/16” Wrench

17
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Tools Needed:
INSTALLATION
Power Drill
7/16” Socket
Driver
U-Bar
NOTE: U-Bars are required on all doors
14’ wide and over.
NOTE: All U-Bars are placed at the top
of the section.
NOTE: The intermediate I section is the
third section from the bottom on a 5
section door. The intermediate II section
is the fourth section from the bottom on
a 5 section door.
NOTE: For doors 16’1” to 18’0” that
have a glazed section, the U-bar needs
to be placed on the Intermediate
section instead of the Lock section on
a 4 section door. On a 5 section door
the U-bar needs to be placed on the
Intermediate II section instead of the
Intermediate I section.
INSTALLATION ON THE TOP SECTION:
Doors 14’ wide and over, locate U-Bar
above top bracket and secure with
(2) 1/4”- 20 x 7/8” self drilling screws
at each end and center stile location.
INSTALLATION ON ALL OTHER
SECTIONS:
NOTE: All WayneMark™ 8200 doors
14’- 0” to 16’- 0” wide, 6’- 0” to 7’- 0”
high (4 section high only) are now
supplied with a 2” U-Bar for the top of
the bottom section.
Place the U-Bar on the section against
the bottom of the hinges. Center the
U-Bar side to side on the section at
the location shown, and secure to the
section using (2) 1/4”- 20 x 7/8” self
drilling screws at each end and center
stile location.
8
U-BAR PLACEMENT FOR BOTTOM, LOCK AND INTERMEDIATE SECTIONS
U-BAR PLACEMENT FOR TOP SECTION
ATTACHING END STILE
U-BAR PLACEMENT FOR TOP SECTION
U-BAR
TOP
BRACKET
ASSEMBLY
TOP SECTION
U-BAR
TOP
SECTION
TOP
SECTION
U-BAR
(2) 1/4”- 20 X 7/8”
SELF DRILLING
SCREWS
Model 46 U-Bar Schedule
Door Width 4 Section 5 Section
8’- 0” to 14’- 11” N/A N/A
15’- 0” to 16’- 0” (1) 2” U-Bar (1) 2” U-Bar
16’- 1” to 18’- 0” (3) 2” U-Bar (3) 2” U-Bar
8000 Series U-Bar Schedule
Door Width 4 Section 5 Section
8’- 0” to 13’- 11” N/A N/A
14’- 0” to 14’- 11” (1) 2” U-Bar (1) 2” U-Bar
15’- 0” to 16’- 0” (1) 2” U-Bar (1) 2” U-Bar
16’- 0” to 18’- 0” (3) 2” U-Bar (3) 2” U-Bar
SIDE PROFILE
HINGE
DOOR
SECTION
U-BAR
ATTACHING CENTER STILE
(2) 1/4”- 20 X 7/8”
SELF DRILLING
SCREWS
(2) 1/4”- 20 X 7/8”
SELF DRILLING
SCREWS
U-BAR
U-BAR
HINGE
HINGE
BOTTOM SECTION
BOTTOM
SECTION

18
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Tools Needed:
Tools Needed:
10
Bottom Section
WEATHER
SEAL
LEVEL
HEADER
Hammer
Wood Shims
JAMB
BOTTOM
SECTION
WOODEN
SHIMS
JAMB
Before installing the bottom section,
the weather seal (may not be included)
must be installed (see PREPARING THE
OPENING on page 10)
Center the bottom section in the door
opening. Level section using wooden
shims (if necessary) under the bottom
section.
9
Vertical Track
3/16” Drill Bit
Power Drill
7/16” Socket
Driver
Tape Measure
Level
BOTTOM SECTION
5/16 X 2” LAG
SCREWS
FLAGANGLE
VERTICAL
TRACK
ASSEMBLY
JAMB
BRACKET
VERTICAL TRACK
ROLLER
JAMB BRACKET
5/16” X 2”
LAG BOLT
IMPORTANT: THE TOPS OF THE
VERTICAL TRACKS MUST BE LEVEL
FROM SIDE TO SIDE. IF THE BOTTOM
SECTION WAS SHIMMED TO LEVEL IT.
THE VERTICAL TRACK ON THE SHIMMED
SIDE, MUST BE RAISED THE HEIGHT OF
THE SHIM.
Position the left hand vertical track
assembly over the rollers of the bottom
section. Make sure the counterbalance
cable is located between the rollers and
the door jamb. Drill 3/16” pilot holes for
the lag screws.
Install the track so that it is aligned with
the bottom of the door.
Secure jamb brackets and flagangles
to the jamb using 5/16 x 2” lag screws.
Hang counterbalance cable over
flagangle. Repeat for the right side.
5/8”
FLAGANGLE HOLE
SELECTION

19
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Tools Needed:
Tools Needed:
INSTALLATION
11 Stacking Sections
Power Drill
7/16” Socket
Driver LOCK SECTION
NOTE: For door section identification see
page 4.
NOTE: Make sure hinges are flipped down,
when stacking another section on top.
With assistance, lift second section and
guide rollers into the vertical tracks.
Keeping the ends of the sections aligned,
install remaining section(s), except top
section, in same manner. Now flip up
hinge leaf, hold tight against section, and
fasten center hinges first, and end hinges
last, using (2) 1/4”- 14 x 5/8” self tapping
screws. Repeat for other section(s) except
top section.
IMPORTANT: PUSH & HOLD THE HINGE
LEAF AGAINST SECTION WHILE SECURING
WITH 1/4”- 14 X 5/8” SELF TAPPING
SCREWS.
NOTE: Install lock at this time (sold
separately) see instructions in OPTIONAL
SIDELOCK INSTALLATION on page 28.
Top Section
Hammer
Nail
Power Drill
7/16 Socket
Driver
Tape Measure
Place the top section in the opening
and vertically align with lower sections.
Temporarily secure the top section by
driving a nail in the header near the
center of the door and bending it over
the top section.
Now flip up hinge leaf against section,
fastening center hinges first, and end
hinges last. (Refer to Step 5).
When installing a door with a torsion
counterbalance system, vertical
track alignment is critical. Position
flagangle between 1-11/16” (43 mm)
to 1-3/4” (44 mm) from the edge of
the door. Tighten the bottom lag screw.
Flagangles must be parallel to the door
sections.
Repeat for opposite side.
IMPORTANT: THE DIMENSION
12
DOOR WIDTH
+3-3/8” TO 3-1/2”

20
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Tools Needed:
Tools Needed:
1-11/16” TO 1-3/4”
FLAGANGLE
TOP
SECTION
NAIL
ROLLER
VERTICAL TRACK
ROLLER AGAINST
VERTICAL TRACK
TOP SECTION
FLAGANGLE
(2) 1/4”- 20 FLANGE
HEX NUTS
VERTICAL TRACK
HORIZONTAL
TRACK
(2) 1/4”- 20 X 5/8”
CARRIAGE BOLTS
To install horizontal track, place the
curved end over the top roller. Align
the bottom of the horizontal track with
the vertical track. Hand tighten the
horizontal track to the flagangle with (2)
1/4”- 20 x 5/8” carriage bolts and (2)
1/4”- 20 flange hex nuts.
Level the horizontal track assembly and
bolt the horizontal angle to the slot in
the flagangle using
(1) 3/8”- 16 x 3/4” hex head bolt and (1)
3/8”- 16 hex nut. Repeat for other side.
Remove the nail that was temporarily
holding the top section in place,
installed in Step 12.
IMPORTANT: FAILURE TO REMOVE NAIL
BEFORE ATTEMPTING TO RAISE DOOR
COULD CAUSE PERMANENT DAMAGE
TO TOP SECTION.
13
9/16” Socket
7/16” Socket
Ratchet Wrench
9/16” Wrench
Level
Hammer
Flat Tip
Screwdriver
Attaching Adjustable Flagangle
to Horizontal Track
BETWEEN THE FLAGANGLES MUST BE
DOOR WIDTH PLUS 3-3/8” (86MM) TO
3-1/2” (89 MM) FOR SMOOTH, SAFE
DOOR OPERATION.
Complete the vertical track installation
by securing the center jamb bracket(s)
and tightening the other lag screws.
Push the vertical track against the
rollers so that the rollers are touching
the deepest part of the curved side of
the track (see illustration). Tighten all
the carriage bolts and nuts.
Repeat for opposite side.
Top Section Continued...