Wayne-Dalton Torquemaster Plus 8000 User manual

This Quick Start Guide is only meant to be used as an aid and
/ or introduction to garage door installation, and does not replace the
complete Installation Instructions and Owner’s manual available on the
web at www.Wayne Dalton.com. 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.
DEFINITION OF DOOR HEIGHTS:
1. Door Heights less than or equal to 8’0” (< = 8’0”) are considered
Standard Lift 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
QUICK START GUIDE IMPORTANT NOTICES!
©Copyright 2015 REV6_06/04/2015Part Number
Table Of Contents
341233
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.
Pre-Installation 2
Important Safety Instructions 2
Removing an Existing Door 2
Preparing the Opening 2
Parts Breakdown 3
Installation 4
Maintenance 11
Cleaning Your Garage Door 11
Painting Your Garage Door 11
Maintaining The Finish On Your Garage Door 11
Operation And Maintenance 11
Warranty 12
Wayne Dalton, a Division Of Overhead Door Corporation
8000/8100/8200
To r q u e Ma s T e r ®P l u s
quick sTarT Guide
MH
sTandard lifT

Important Safety Instructions
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 QUES-
TION 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.
WARNINGWARNING
PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, EN-
SURE 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
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 / Prepar-
ing 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
WEATHERSTRIPS (MAY NOT BE INCLUDED):
Depending on the size of your door, you may have to cut or trim the weatherstrips (if neces-
sary) 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 track systems: 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.
2
Pre-Installation

3
A. FLAG ANGLES (AS REQUIRED):
A1. Fully Adjustable (F.A.) Flag Angles
A2. Quick Install (Q.I.) Flag Angles
B. JAMB BRACKETS (AS REQUIRED):
B1. Fully Adjustable (F.A.) Jamb Brackets
B2. Quick Install (Q.I.) 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.), Anti-Pinch
D2. Single Graduated End Hinges (S.E.H.), Industry Standard
D3. Double Graduated End Hinges (D.E.H.), Anti-Pinch
D4. 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 (AS REQUIRED):
F1. Top Fixture Bases
F2. Top Fixture Slides
F3. Top Fixture Assemblies
G. STRUT(S) (AS REQUIRED):
G1. Strut (U-shaped)
G2. Strut (A-symmetrical)
H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):
H1. Drawbar Operator Bracket – For Models 9600/9400/9100/5140/5120
H2. Drawbar Operator Bracket – For Models 9700/9800
I. TRACKS:
I1. Left Hand Horizontal Track Assembly
I2. Right Hand Horizontal Track Assembly
I3. Left Hand Vertical Track
I4. Right Hand Vertical Track
I5. Left Hand Riveted Vertical Track Assembly
I6. Right Hand Riveted Vertical Track Assembly
J. TORQUEMASTER PLUS®SPRING ASSEMBLY:
J1. Center Bracket Bushing Assembly
J2. TorqueMaster®Spring Tube (Single Or Double Springs)
J3. Left Hand End Bracket (Double Springs Only)
J4. Right Hand End Bracket (Disconnect Cable Guide)
J5. Left Hand And Right Hand Cable Drum Assemblies
J6. Idler bracket (Single Spring Only)
J7. Left Hand And Right Hand Drum Wraps (Optional)
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
I5.
A2.
A2. A1.
B2.
B1.
B2.
B1.
C1.
C2.
C1.
C1.
D1.
D3.
D4.
E4.
E1.
E2.
E3.
F1.
F2.
F1.
F2.
G1.
G2.
H1.
I4.
I2.
I1.
I3.
K1.
K1.
J3.
J4.
J1.
J6.
J5.
J2.
Lower hole
of hole/
slot pattern
3rd
hole set
Top of vertical
track
B1. (Fully
Adjustable
Feature)
2nd
hole set
1st
hole set
B2. (Quick
Install
Feature)
3rd hole
set
Top of vertical
track
2nd
hole set
1st hole
set Middle
hole
Bottom
hole
Top
hole
D2.
H2.
NOTE: The illustrations shown on this page are general
representations of the door parts. Each specific door
models may have unique variations.
L1.
L1.
J5.
J7.
J7.
F3.
F3.
A1.
I6.
PARTS BREAKDOWN

INSTALLATION
Before installing your door, be certain that you have read and followed all of the instruc-
tions 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
Tools Required: Safety glasses, Leather gloves
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.
1/4 Turn
Flag angle
Vertical
track
Lower Quick
Install tab
Quick Install
feature
Fully Adjustable Flag Angles
Tools Required: Safety glasses, Leather gloves
2
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.
Horizontal Track Angles
Tools Required: Hammer, Safety glasses, Leather gloves
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.
Horizontal track
angle
Key slots
Horizontal
track
Alignment
hole
Quick
Install
tabs
Quick Install tabs
in place
Quick Install Jamb Brackets
Tools Required: Tape measure, Safety glasses, Leather gloves
4
NOTE: If you have Fully Adjustable jamb brackets, 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.
JAMB BRACKET SCHEDULE
DOOR
HEIGHT
TRACK
LENGTH
1ST SET 2ND SET 3RD SET
6’0” 64”
(1626
mm)
9 M 11 M NA
6’3” 67”
(1702
mm)
9 B 11 M NA
6’6” 70”
(1778
mm)
9 M 10 B NA
6’9” 73”
(1854
mm)
9 M 10 B NA
7’0” 76”
(1930
mm)
9 M 10 B NA
7’6” 82”
(2083
mm)
9 T 10 M 11 M
7’9” 85”
(2159
mm)
9 T 10 M 11 M
8’0” 88” 9 T 10 M 11 M
B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE
Q.I. jamb
bracket
Jamb bracket
in place
Mounting flange
Q.I. tab
1st hole set
Bottom hole
Middle hole
Top hole
Vertical track
2nd hole set 3rd hole set
Top of track
Fully Adjustable Jamb Brackets
Tools Required: Tape measure, Safety glasses, Leather gloves
5
NOTE: If you have Quick Install jamb brackets, Riveted Track or Angle Mount Track, skip this
step.
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.
Graduated Hinge Attachment
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Level, Safety
glasses, Leather gloves
6
NOTE: Refer to door section identification, located in the pre-installation section of this
manual.
NOTE: The graduated hinges can be identified by the number stamped on the lower hinge
leaf.
NOTE: 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.
4

NOTE: The #4 graduated end hinges serves as end hinges on the Intermediate II section
(used only on the fourth section of a five section high door).
Starting on the left hand side of the bottom section, align the lower hinge leaf of the #1
graduated end hinge over the holes, located at the top of the end caps. Attach lower leaf to
the end caps with (2) 1/4” - 14 x 5/8” self tapping screws. Repeat for other side. Next, align
the lower hinge leaf of the #1 center hinges with the pre-punched holes at each center stile
location(s), located at the top of the bottom section. Attach lower hinge leaf to the center stile
with (2) 1/4” - 14 x 5/8” self tapping screws. Insert a short stem track roller into the hinge
tube of the #1 graduated end hinges.
IMPORTANT: ONCE THE 1/4” - 14 X 5/8” SELF TAPPING SCREWS ARE SNUG AGAINST THE
LOWER HINGE LEAFS, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE MAXIMUM
DESIGN HOLDING POWER.
Repeat graduated hinge attachment using the appropriate graduated end hinges for all
remaining sections except the top 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.
IMPORTANT: ONCE THE 1/4” - 14 X 5/8” SELF TAPPING SCREW IS SNUG AGAINST THE
LOWER HINGE LEAF, TIGHTEN AN ADDITIONAL 1/4 TO 1/2 TURN TO RECEIVE MAXIMUM
DESIGN HOLDING POWER.
Strut (U-Shaped)
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Level, Safety
glasses, Leather gloves
7
NOTE: Refer to door section identification, located in the pre-installation section of this
manual or refer to Parts Breakdown.
Using the strut schedule, determine the placement of the struts for your door width and door
height.
INSTALLATION ON THE TOP SECTION:
Locate and center the strut at the top of the top section surface. Secure strut to top section
using (2) 1/4” - 20 x 7/8” self drilling screws at each end and at each center stile locations.
INSTALLATION ON ALL OTHER SECTIONS:
NOTE: All struts are placed at the top of the sections and up against the bottom of the gradu-
ated hinges, for the intermediate, lock and bottom sections.
Locate and center the strut onto the section surface and up against the bottom of the hinges.
Center the strut side to side. Secure strut to the section using (2) 1/4” - 20 x 7/8” self drilling
screws at each end and center stile locations.
Strut Schedule
Door Width 4 Section High Door 5 Section High Door
8’0” – 13’11” N/A N/A
14’0” – 16’0” (1) Strut Top Section (2) Struts Top and Bottom
Sections
16’1” – 18’0” (3) Struts Top, Lock and Bottom
Sections
(3) Struts Top, Intermediate I
and Bottom Section
18’1” – 20’00” (4) Struts All Sections (5) Struts, All Sections
Top Fixtures
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Level, Safety
glasses, Leather gloves
8
Align the upper-center hole of top fixture base with the hole in the end stile of the top section,
as shown. Ensure the top fixture base is level and aligned with edge of the top section. Se-
cure with (4) 1/4” - 20 x 7/8” self drilling screws, one in each corner of the top fixture base.
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.
Cable Drum Assemblies and Track Rollers
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Level, Safety
glasses, Leather gloves
9
NOTE: Refer to door section identification, located in the pre-installation section of this
manual or refer to Parts Breakdown.
Starting on the left hand side, 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, using (2) 1/4” - 20 x
11/16” self drilling screws (1) 1/4” - 20 x 5/8” tamper resistant screw. Repeat for other side.
NOTE: Only doors provided to professional installers, who have the required tools will be sup-
plied with a tamper-resistant fastener. Use a 1/4” - 20 x 11/16” self drilling screw in bottom
bracket, if not provided with a tamper-resistant screw.
NOTE: Cable drum assemblies are marked right and left hand.
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.
Uncoil the counterbalance lift cables from the cable drum assemblies, making sure you place
the left hand cable loop on the left hand milford pin of the bottom corner bracket and the
right hand cable loop on the right hand milford pin of the bottom corner bracket.
NOTE: Check to ensure cable loops fits tightly over the milford pins.
Insert a short stem track roller with a roller spacer into each of the bottom corner brackets.
NOTE: Larger doors will use long stem track rollers with double graduated end hinges.
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.
Step Plate
Tools Required: Power Drill, 5/16”/7/16” Drill bits, 1/4” Wrench, Tape measure,
Phillips head screwdriver, Level, Safety glasses, Leather gloves
10
NOTE: Depending on your door, you may have two different kinds of Step Plates or two of the
same kind of Step Plates. Refer to Package Contents, to determine which Step Plates you
have.
IF YOU HAVE TWO OF THE SAME KINDS OF STEP PLATES:
Locate the center most center stile of the bottom section of the door. On the inside of the
door, center the step plate on the center most stile no higher than 6” from the bottom of
the door. Using the step plate holes as a template, drill a 5/16” dia. hole along each side of
the center stile, through the face of the door. Drill through insulation and door’s face on an
insulated door.
IMPORTANT: BE EXTREMELY CAREFUL TO KEEP DRILL STRAIGHT.
Mount the inside step plate and the outside step plate back to back, straddling the center
stile. Secure with (2) 1/4” - 20 x 2-3/4” carriage bolts and 1/4” - 20 hex nuts.
IMPORTANT: DO NOT MOUNT THE STEP PLATE HIGHER THAN 6” FROM THE BOTTOM OF
THE SECTION.
IF YOU HAVE TWO DIFFERENT KINDS OF STEP PLATES:
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.
NOTE: Do not drill through or enlarge holes on the inside of the door.
NOTE: After completing this step, continue with Step Lift Handles.
Lift Handle
Tools Required: Power Drill, 9/32”/1/2” Drill bits, 1/4” Wrench, Tape measure,
Phillips head screwdriver, Level, Safety glasses, Leather gloves
11
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.
NOTE: Do not drill through or enlarge holes on the inside of the door.
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.
Bottom Section
Tools Required: Tape measure, Level, Wooden shims (if necessary), Safety
glasses, Leather gloves
12
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.
Vertical Tracks
Tools Required: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure,
Level, Step ladder, Safety glasses, Leather gloves
13
NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag
Angles or you may have Riveted 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
5

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 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.
Starting on the left hand side of the bottom section, remove the nail. Position the left hand
vertical track assembly over the track rollers of the bottom section. Make sure the coun-
terbalance 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, Fully Adjustable Flag Angles or Riveted Vertical Track As-
semblies: 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.
Stacking Sections
Tools Required: Power drill, 7/16” Socket driver, Tape measure, Level, Step lad-
der, Safety glasses, Leather gloves
14
NOTE: Refer to door section identification, located in the pre-installation section of this
manual.
NOTE: The sections can be identified by the graduation of the factory installed graduated end
hinges. The smallest graduated end hinge on section should be stacked on top of the bottom
section, with each graduated end hinge increasing as the sections are stacked, see Parts
Breakdown.
NOTE: Make sure end and center hinges are flipped down, when stacking another section
on top.
Place 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 7/8” self-drilling screws.
Repeat same process for other sections, except top section.
IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE
SECURING WITH 1/4” - 20 X 7/8” SELF-DRILLING 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.
Top Section
Tools Required: Power drill, 7/16” Socket driver, 7/16” Wrench, Step ladder,
Tape measure, Safety glasses, Leather gloves
15
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 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 OPERA-
TION.
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.
Horizontal Tracks
Tools Required: Ratchet wrench, 9/16” 7/16” Socket, 9/16” 7/16” Wrench, Step
ladder, Tape measure, Safety glasses, Leather gloves
16
NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable Flag
Angles or you may have Riveted Vertical Track Assemblies. Refer to Package Contents / Parts
Breakdown, to determine which Flag Angles / Vertical Track Assemblies you have.
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.
Horizontal
track
Flag angle
Quick
Install tab
Key slot
Quick
Install tab
in place
Tracks flush
3/8”-16
Hex nut
Horizontal track
angle
3/8”-16 x 3/4”
Truss head bolt
Flag angle
FOR OTHER 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.
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.
Adjusting Top Fixtures
Tools Required: 7/16” Wrench, Step ladder, Tape measure, Safety glasses,
Leather gloves
17
ADJUSTING TOP FIXTURE SLIDE:
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 to secure the top fixture slide to the top fixture base. Repeat for other side.
REVERSING THE TOP FIXTURE SLIDE, IF NEEDED:
NOTE: Depending on your application, you may have to reverse the top fixture slide for more
adjustability, prior to securing it to the top fixture base.
Remove the top fixture slide by removing the (2) 1/4” - 20 flanged hex nuts and the (2) 1/4”
- 20 x 5/8” carriage bolts. Remove the track roller from the top fixture slide and flip the top
fixture slide in the opposite direction. Re-insert the track roller back into the top fixture slide
and loosely fasten the top fixture slide to the top fixture base by re-using the (2) 1/4” - 20 x
5/8” carriage bolts and (2) 1/4” - 20 flange hex nuts. Repeat same process for other side.
Now follow the instructions at the top of this step “Adjusting top fixture slide(s)”.
TorqueMaster®Spring Tube
Tools Required: Safety glasses, Leather gloves
18
TorqueMaster®springs come lubricated and pre-assembled inside the TorqueMaster®spring
tube. To prepare for install, lay the spring tube assembly on the floor, inside garage, in front of
the door, and with the labeled end to the left. Next, remove the shipping boots from the ends
of the TorqueMaster®spring tube.
TorqueMaster®
spring tube
Label Shipping
boot
Shipping
boot
Shipping boot
TorqueMaster®
spring tube
Label
Center Bracket Bushing Assembly
Tools Required: Safety glasses, Leather gloves
19
Being cam shaped, the center bushing only fits one way. Slide the center bracket bushing as-
6

sembly towards the center of the TorqueMaster®spring tube, from the right side, as shown.
Center bracket bushing assembly
TorqueMaster®
spring tube
Center bracket
Center bushing
Cam peak
Drum Wraps (Optional)
Tools Required: Safety glasses, Leather gloves
20
NOTE: If you don’t have drum wraps (optional), then skip this step. Refer to Package Con-
tents / Parts Breakdown, to determine if you have drum wraps.
Drum wraps are marked right and left hand. Beginning with the left hand side, slide the left
hand drum wrap onto the TorqueMaster®spring tube. Repeat for the right hand side. The
drum wrap will be secured later, in Step, Securing Drum Wraps.
TorqueMaster®spring tube
Label
Left hand
drum wrap
Right hand
drum wrap
Cable Drum Assemblies
Tools Required: Tape measure, Step ladder, Safety glasses, Leather gloves
21
Shake the TorqueMaster®spring tube assembly gently to extend the winding shafts out about
5” on each side. For single spring applications, there will be no left hand spring in the
TorqueMaster®spring tube assembly. Lift the TorqueMaster®spring tube assembly and rest it
on top of the flag angles.
NOTE: Cable drum assemblies are marked right and left hand. Cable drums and TorqueMas-
ter®spring tube assembly are cam shaped to fit together only one way.
Starting on the right hand side, pre-wrap the cable drum with the counterbalance lift cable
1-1/2 wraps, as shown. Position the TorqueMaster®spring tube assembly so the cam peak
is pointing straight up. Slide the cable drum over the winding shaft until the cable drum
seats against the TorqueMaster®spring tube assembly. The winding shaft must extend past
the cable drum far enough to expose the splines and the grooves. Align the winding shaft
grooves with the round notch in the flag angle.
FOR DOUBLE SPRING APPLICATIONS: Repeat for left hand side.
FOR SINGLE SPRING APPLICATIONS: Insert the idler bracket into the left hand cable drum.
Lightly press the idler bracket into the cable drum until two distinct clicks are heard, or the
bracket is inserted all the way.
IMPORTANT: ENSURE THE SNAPS ON THE IDLER BRACKET (LEFT HAND SIDE) ARE EN-
GAGED INTO THE LEFT HAND CABLE DRUM, SO THAT IT DOES NOT COME BACK OUT.
NOTE: The idler bracket is designed for permanent assembly. Do not attempt to remove idler
bracket once inserted into the cable drum.
Pre-wrap the left hand cable drum with the counterbalance lift cable 1-1/2 wraps and slide
the cable drum over the TorqueMaster®spring tube assembly. Slide the TorqueMaster®
spring tube assembly into the cable drum until the cable drum seats up against the Torque-
Master® spring tube assembly.
NOTE: The idler bracket must extend past the cable drum far enough to expose the grove.
Align the idler bracket groove with the round notch in the flag angle.
TorqueMaster®spring
tube assembly
Cam peak
straight
Winding shaft
Counterbalance lift cable
1-1/2 wraps
Grooves
Cable drum
Splines
Round notch
Winding
shaft
Right cable
drum
5”
Flag
angle
Idler
bracket
Left hand
cable drum
Idler
bracket Left hand
cable drum
Groove
Snap
Snap
Snaps
TorqueMaster®spring tube assembly
Counterbalance
lift cable
1-1/2 wraps
Groove Left
hand
cable
drum
Round
notch
Flag
angle
Idler
bracket
Groove
Left hand
cable drum
End Brackets
Tools Required: Power drill, 3/16” Drill bit, 7/16” Socket driver, 1/2” Wrench,
Tape measure, Step ladder, Safety glasses, Leather gloves
22
IMPORTANT: WARNING TAGS MUST BE SECURELY ATTACHED TO END BRACKET(S).
NOTE: On single spring applications, the idler end bracket was positioned in a previous step,
but must be fastened in this step.
NOTE: Prior to fastening the end bracket(s) / idler end bracket into the door jamb, pilot drill
using a 3/16” drill bit.
Beginning with the right hand side, slide the end bracket onto the winding shaft so that the
splines in the ratchet wheel fit onto the winding shaft grooves. Attach the end bracket to the
flag angle using (1) 5/16” - 18 x 3/4” carriage bolt, (1) 5/16” washer and (1) 5/16” - 18 hex
nut. Then secure the end bracket to the jamb using (1) 5/16” x 1-5/8” lag screw.
NOTE: If ratchet wheel falls out of end bracket, refer to illustration for proper insertion
orientation.
FOR DOUBLE SPRING APPLICATIONS: Repeat same process for left hand end bracket.
FOR SINGLE SPRING APPLICATIONS: Secure the idler bracket to the flag angle using (1)
5/16” - 18 x 3/4” carriage bolt, (1) 5/16” washer and (1) 5/16” - 18 hex nut. Then secure
the idler bracket to the jamb using (1) 5/16” x 1-5/8” lag screw.
IMPORTANT: FOR SINGLE SPRING DOORS, ENSURE THE LEFT HAND CABLE DRUM BEARING
IS ALL THE WAY TO THE LEFT AND UP AGAINST THE FLAG ANGLE. IF THE CABLE DRUM IS
PULLED AWAY FROM THE FLAG ANGLE, THEN THE IDLER BRACKET CAN RUB AGAINST THE
CABLE DRUM CAUSING NOISE.
7

Grooves
Warning tag
Disconnect cable
guide hole
Splines
Winding
shaft
Right hand end bracket
Flag angle
Ratchet wheel
(teeth pointing
upwards)
Black tooth
5/16” x 1-5/8”
Lag screw
5/16” -18 x 3/4”
Carriage bolt
5/16”
Washer
Flag angle
5/16” Hex nut
Right hand
end bracket
TorqueMaster®
spring tube
assembly
Idler bracket
Left
hand
cable
drum
Left hand
cable drum
Flag angle
5/16” x 1-5/8”
Lag screw
5/16” -18 x 3/4”
Carriage bolt
5/16”
Washer
5/16” Hex
nut
Flag angle
Left hand
cable drum
bearing
TorqueMaster®
spring tube
assembly
Idler bracket
Flag angle
Left hand
cable drum
bearing
Left hand
cable drum
bearing
Idler bracket
Flag angle
Securing Center Bracket Bushing Assembly
Tools Required: Power drill, 3/16” Drill bit, 7/16” Socket driver, 1/2” Wrench,
Level, Tape measure, Step ladder, Safety glasses, Leather gloves
23
IMPORTANT: TORQUEMASTER®SPRING TUBE MUST BE LEVEL BEFORE SECURING CENTER
BRACKET BUSHING ASSEMBLY TO HEADER.
To locate the center bracket bushing assembly, mark the header halfway between the flag
angles and level the TorqueMaster®spring tube. Drill 3/16” pilot holes into header for the lag
screws. Fasten the center bracket bushing assembly to the header using (2) 5/16” x 1-5/8”
lag screws.
(2) 5/16” x 1-5/8”
Lag screws
TorqueMaster®
spring tube
Center bracket
bushing assembly
Securing Door For Winding Spring(s)
Tools Required: Vice Clamps, Step ladder, Safety glasses, Leather gloves
24
With the door in the fully closed position, place vice clamps onto both vertical tracks just
above the third track roller. This is to prevent the garage door from rising while winding
spring(s).
NOTE: Check the following before attempting to wind 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. TorqueMaster® spring tube is installed correctly.
e. 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
spring(s).
WARNINGWARNING
FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW
DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.
Vice clamps above third track
roller on both sides of door
Bottom section
Vice clamps attached to inner
and outer rail of vertical track
Lift Cable Adjustments
Tools Required: Locking pliers, Flat tip screwdriver, Step ladder, Tape measure,
Pliers / Wire cutters, Safety glasses, Leather gloves
25
Starting on the right side, adjust the cable drum assembly by rotating the drum until the set
screw faces directly away from the header. The position of the cam peak on the TorqueMas-
ter®spring tube should be pointing straight up.
Loosen the set screw no more than 1/2 turn. Ensure counterbalance lift cable is aligned and
seated in the first and second grooves of the cable drum. Pull on the end of the cable to
remove all cable slack.
Snug the set screw and then tighten an additional 1-1/2 turns. Measure approximately 6” of
cable and cut off excess cable. Insert end of the cable into the hole of cable drum. Repeat for
left hand cable drum assembly.
IMPORTANT: ENSURE THE COUNTERBALANCE LIFT CABLE IS ALIGNED AND SEATED IN THE
FIRST AND SECOND GROOVES OF THE CABLE DRUM PRIOR TO WINDING SPRINGS.
NOTE: Illustration shows the right hand cable drum assembly.
Cam peak
pointing straight up
Insert
cable here
6”
Cut cable here
First and
second grooves
Set screw
TorqueMaster®
spring tube
Counterbalance
lift cable
8

Winding Spring(s)
Tools Required: Ratchet wrench, 5/8” Socket, 3” Socket extension, Pliers / Wire
cutters, Flat tip screwdriver, Step ladder, Tape measure, Safety glasses, Leather
gloves
26
WARNINGWARNING
WINDING TORSION SPRING(S) IS AN EXTREMELY DANGEROUS PROCE-
DURE AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM
WARNINGWARNING
IT IS RECOMMENDED THAT LEATHER GLOVES BE WORN WHILE WINDING
SPRINGS. FAILURE TO WEAR GLOVES MAY CAUSE INJURY TO HANDS.
Double check to ensure the counterbalance lift cable is aligned in the first and second
grooves of the cable drum, see step Lift Cable Adjustments. There are two methods for
counting the spring turns as you wind. One method is to identify the black tooth on the
ratchet wheel inside of the end bracket. When the wheel makes one revolution and the tooth
returns to its starting point, one turn has been made. The other method is to make a mark on
the winding shaft (or socket) and end bracket, and count your turns in this manner.
Starting on the right hand side, turn the pawl knob on the end bracket to the upper position.
Using a ratchet wrench with a 5/8” socket and a 3” extension, wind the spring by rotating the
winding shaft counter clockwise, while watching either the black tooth on the ratchet wheel
or the mark on the winding shaft.
NOTE: A 3” extension is recommended for added clearance from the horizontal track angle.
IMPORTANT: PAWL KNOB MUST BE IN UPPER POSITION TO ADD / REMOVE REQUIRED
NUMBER OF SPRING TURNS.
After 2 to 3 turns, remove the ratchet wrench and adjust the counterbalance lift cable on the
left side. Ensure counterbalance lift cables are in the first and second grooves of the cable
drums, as shown in step Lift Cable Adjustments.
NOTE: Single spring applications require no spring winding on the left hand side, but lift
cable tension needs to be adjusted.
IMPORTANT: COUNTERBALANCE LIFT CABLE TENSION MUST BE EQUAL ON BOTH SIDES
PRIOR TO FULLY WINDING SPRINGS.
See the Winding Spring Turn Chart for the required number of winding turns:
FOR SINGLE SPRING APPLICATIONS:
Return to the right hand end bracket and continue winding the spring to the required number
of turns for your door following the double spring instructions below. Place pawl knob in
lower position.
FOR DOUBLE SPRING APPLICATIONS:
Either use the black tooth on the ratchet wheel for winding reference or place a mark on the
winding shaft and end bracket. Place the ratchet wrench with 5/8” socket and a 3” extension
onto the left hand winding shaft end. To wind the spring, rotate the winding shaft clockwise,
while watching the black tooth on the ratchet wheel or the mark on the winding shaft. Rotate
the winding shaft to the required number of winding turns for your door. Then return to the
right hand side and wind the right hand spring to the required number of turns. Place pawl
knob in lower position on both sides.
IMPORTANT: MARK THE NUMBER OF SPRING TURNS ONTO THE END BRACKET WARNING
TAG.
NOTE: Since total turns to balance door can deviate from winding spring turn chart values
by ± 1/2 turn, adjustments to the recommended number of turns may be required after rear
back hangs are installed.
WINDING SPRING TURN CHART
DOOR HEIGHT SPRING TURNS
6’-0” 14
6’-3” 14-1/2
6’-5” 15
6’-6” 15
6’-8” 15-1/2
6’-9” 15-1/2
7’-0” 16
7’-3” 16-1/2
7’-6” 17
7’-9” 17-1/2
8’-0” 18
Winding
shaft
3”
Extension
End bracket
Marks
Black tooth
on ratchet
wheel
Pawl knob in
lower position
Pawl knob in
upper position
5/8”
Socket
Ratchet
wrench
Mark the number of
spring turns onto the
end bracket warning tag
Securing Drum Wraps (Optional)
Tools Required: Step ladder, Safety glasses, Leather gloves
27
NOTE: If you don’t have drum wraps (optional), then skip this step. Refer to Package Con-
tents / Parts Breakdown, to determine if you have drum wraps.
Starting on the left hand side, position the left hand drum wrap, as shown. Slide the left hand
drum wrap over the cable drum assembly.
IMPORTANT: PULL THE COUNTERBALANCE LIFT CABLE AWAY FROM THE HEADER TO
CLEAR THE LATCH, WHILE SIMULTANEOUSLY SLIDING THE DRUM WRAP AGAINST THE LAST
RIB UNTIL THE THREE CATCHES ENGAGE THE 3RD RIB.
Secure the hinge latch by rotating upward until a distinct snap is felt. Confirm the catch is
fully engaged by lightly tugging on it. Repeat the same process for right hand side.
Last rib Drum wrap Cable
drum
3rd rib
3 catches
Counterbalance
lift cable. Pull to
clear latch Hinged latch
Re-engage
hinged latch
3rd rib
Rear Back Hangs
Tools Required: Ratchet wrench, Socket: 1/2” 5/8”, Wrench: 1/2” 5/8”, 3”
Socket extension, (2) Vice clamps, Step ladder, Tape measure, Safety glasses,
Leather gloves
28
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.
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.
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
9

Perforated Angle Gauge Weight Limitations:
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” MAXI-
MUM 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 weather-
strips 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 weath-
erstrips too tightly against the face of door.
Vice clamp
Horizontal tracks
2nd Track roller
Vice clamp
5/16”-18 x 1-1/4”
Hex bolt must extend into the
track to serve as a roller stop
Perforated angle
Sound framing
members
Horizontal
track
(3) 5/16” Bolts and nuts
Perforated angle bolted
using (2) 5/16” x 1-5/8”
hex head lag screws to
ceiling member and
parallel to door
Perforated angle
Sound framing
members
Horizontal
track
(3) 5/16”
Bolts and nuts
Perforated angle bolted
using (2) 5/16” x 1-5/8”
hex head lag screws to
ceiling member and
parallel to door
5/16”-18 x 1-1/4”
Hex bolt must extend into the
track to serve as a roller stop
Horizontal tracks
Door edges
3/4” To 7/8”
3/4” To 7/8”
Balancing Door
Tools Required: Ratchet wrench, Socket: 5/8”, Wrench: 5/8”, 3” Socket exten-
sion, (2) Vice clamps, Step ladder, Tape measure, Safety glasses, Leather gloves
29
NOTE: Windows will cause the top section to be significantly heavier than the remaining
sections. Wayne Dalton attempts to balance the door at the top and bottom. To prevent any
sudden door acceleration between the top and bottom, we recommend motor operating all
doors with windows. Doors with windows in the top section should not be manually operated.
Remove any vice clamps. Lift the door and check its balance. Adjust spring(s) if door lifts by
itself (hard to pull down) or if door is difficult to lift (easy to pull down). Anytime spring adjust-
ments are made, ratchet pawl knob must be in the upper position. An unbalanced door can
cause TorqueMaster®Plus operation problems.
Close the door and place vice clamps onto both vertical tracks just above the third track
roller. This is to prevent the garage door from rising while adjusting the counterbalance
spring(s).
IMPORTANT: TO ADJUST SPRINGS, ONLY ADD OR REMOVE A MAXIMUM OF 3/10 OF
A TURN (THREE TEETH ON THE RATCHET WHEEL) AT A TIME. BOTH SIDES NEED TO BE
ADJUSTED EQUALLY ON DOUBLE SPRING DOORS.
Add spring tension: The ratchet wheel is made of 10 teeth. To add spring tension, ensure
the ratchet and socket is set so that it will tighten counter clockwise on the right hand side
and clockwise on the left hand side. Place pawl knob in upper position. Place the ratchet
wrench with 5/8” socket and 3” socket extension onto the winding shaft, pull down to add
3/10 of a turn. Watch as three teeth of the ratchet wheel pass over the pawl, creating three
“clicks”. Place pawl knob in lower position.
Remove spring tension: To remove spring tension, place a regular 5/8” wrench onto the
winding shaft. Place pawl knob in upper position. Pull down on the wrench to relieve pressure
between the pawl and the ratchet wheel. Push in on the pawl to allow the three ratchet wheel
teeth to pass by the pawl, as you carefully allow the wrench to be rotated upward by the
spring tension, release the pawl to allow it to engage with the ratchet wheel. Place pawl knob
in lower position.
IMPORTANT: BE PREPARED TO HOLD THE FULL TENSION OF THE SPRING.
IMPORTANT: DO NOT ADD OR REMOVE MORE THAN 1 SPRING TURN (1 SPRING TURN
EQUALS 10 TEETH ON RATCHET WHEEL) FROM THE RECOMMENDED NUMBER OF TURNS
SHOWN ON THE WINDING SPRING TURN CHART.
If the door still does not operate easily, lower the door into the closed position, unwind
spring(s) completely, and recheck the following items:
1.) Check the door for level.
10

2.) Check the TorqueMaster®spring tube and flag angles for level and plumb.
3.) Check the distance between the flag angles, which must be door width plus 3-3/8” to
3-1/2”.
4.) Check the counterbalance lift cables for equal tension, adjust if necessary.
5.) Rewind the spring(s).
6.) Make sure door isn’t rubbing on jambs.
Ratchet
wrench
End bracket
Pawl
Winding
shaft
Ratchet wheel
Pawl knob in
lower position
Pawl knob in
upper position
Pawl
3”
extension
5/8” Socket
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 aestheti-
cally pleasing finish of the garage door, a periodic washing of the garage door is recom-
mended.
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 solvent-
based cleaners of any kind.
Painting Your Garage Door
Refer to Instruction Insert “Field Painting and Finishing Fiberglass or Steel Door Sec-
tions”.
Maintaining The Finish
On Your Garage Door
If the factory finish is beginning to fade, the door may require a field applied top clear coat.
Depending on environment and usage, this may be necessary after 1 to 3 years of use. Refer
to Instruction Insert “Field Painting and Finishing Fiberglass Or Steel Door Sections”.
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 opera-
tor 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, BRACK-
ETS, 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 MANUFAC-
TURER’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 do-
ing 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
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.
11

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.
WARRANTY
Limited Warranty
Models 8000, 8100, 8200
Wayne Dalton, a division of Overhead Door Corporation (“Seller”) war-
rants to the original purchaser of the Models 8000, 8100, 8200 (“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:
TEN (10) YEARS from the date of installation 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.
TEN (10) YEARS on Product hardware and tracks (except springs).
ONE (1) YEAR on all other component and parts.
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 defec-
tive 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 origi-
nal purchaser of the Product only, and is not transferable or assignable. This
warranty applies only to Product installed in a residential or other non-com-
mercial application. It does not cover any Product installed in commercial or
industrial building applications. This warranty does not apply to any unauthor-
ized 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, INCLUD-
ING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED IN TIME TO THE AP-
PLICABLE 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 conse-
quential 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 distribu-
tor 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 pur-
chase 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: __________________________________
_____________________________________
__________________________________
_____________________________________
12

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.
Thank you for your purchase.
PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE
AFTER INSTALLATION IS COMPLETE, FASTEN THIS
MANUAL NEAR GARAGE DOOR FOR EASY REFERENCE.