Wayne Dalton TorqueMaster Plus 8000/8100/8200 garage door Installation Instructions And Owner’s Manual

Ta b l e
8000/8100/8200
TorqueMaster® Plus
Standard Lift
PO
Installation Instructions And Owner’s Manual
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.
Of
C o n te n ts
Pre-Installation2
Important Safety Instructions
2
Tools Required
2
Package Contents
2
Door Section Identification
3
Removing an Existing Door
3
Preparing the Opening
3
Parts Breakdown
5
Installation6
Optional Installation
15
Inside Lock
15
Pull Down Rope
15
Maintenance17
Cleaning Your Garage Door
17
Painting Your Garage Door
17
Maintaining The Finish On Your Garage Door
17
Operation And Maintenance
17
Warranty18
IMPORTANT NOTICES!
Wayne Dalton highly recommends that you read and fully understand
the Installation Instructions and Owner’s Manual before you attempt this
installation.
To avoid possible injury, read the enclosed instructions carefully before
installing and operating the garage door. Pay close attention to all
warnings and notes. After installation is complete, fasten this manual
near garage door for easy reference.
The complete Installation Instructions and Owner’s Manual are available at no
charge from:
Wayne Dalton, a Division Of Overhead Door Corporation,
P.O. Box 67, Mt. Hope, OH., 44660, Or Online At www.Wayne-Dalton.com
©Copyright 2015 Wayne Dalton, a Division Of Overhead Door Corporation
Part Number
353179
REV1_06/04/2015
Pre-Installation
IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING
LOOKING OUT
Important Safety Instructions
Tools Required
DEFINITION OF KEY WORDS USED IN THIS MANUAL:
WARNING
INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH; IF NOT
AVOIDED, COULD RESULT IN SEVERE OR FATAL INJURY.
CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT FROM FAILURE TO
FOLLOW INSTRUCTIONS.
IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION.
NOTE: Information assuring proper installation of the door.
READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUESTION ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A
TRAINED DOOR SYSTEMS TECHNICIAN DO THE INSTALLATION OR REPAIRS.
Power drill
Flat tip screwdriver
Tape measure
Drill bits: 1/8”, 3/16”, 9/32”,
7/16”, 1/2”
Pliers / Wire cutters
Step ladder
Ratchet wrench
Needle nose pliers
Level
Socket driver: 7/16”
Locking pliers
Pencil
Sockets: 7/16”, 1/2”, 9/16”,
5/8”
(2) Vice clamps
Saw horses
Socket extension: 3”
Wrenches: 7/16”, 1/2”, 9/16”,
5/8”
Leather gloves
Phillips head screwdriver
Hammer
Safety glasses
Package Contents
1.
2.
READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.
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 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.
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.
NOTE: Depending on the door model, some parts listed will not be supplied if not required.
Rear Back Hangs may not be included with your door.
Door sections (as required)
TorqueMaster® spring tube
Vertical tracks RH/LH
Horizontal tracks RH/LH
Flag angles RH/LH (as required)
ED
SIDE
VIEW
ENGAG
t Pawl
Left
Idler bracket
Jamb brackets hand end bracket Right hand
Center bracket
(as required) end bracket bushing assembly (single spring only)
(as required)
VIEW
Ratche
EATH
NDERN
Drum wraps
RH/LH (as required)
(2) Top fixture
assemblies
(1) Step plates
(as required)
WARNING
PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, ENSURE YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE
INSTALLATION INSTRUCTIONS. OTHERWISE, THE SPRING FITTINGS MAY
RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND
COULD RESULT IN SEVERE OR FATAL INJURY.
(2) 5/16” Washers
2
Cable drum
Graduated
assemblies RH/LH hinges (as required)
Bottom corner
brackets RH/LH
Track rollers Strut (U-shaped) Weatherstrips &
Pull down
(as required)
(if included) nails (If included) rope (if included)
(1) Step plate
(as required)
(2) Step plates
(as required)
(2) 1/4” - 20 x 5/8”
Tamper resistant screws
(2) Lift handles &
Spacers
(2) Roller
spacers
3/8”-16 x 3/4” Hex bolts
(as required)
Warning label
1/4”-20 x 11/16”
Self drilling
screws (as required)
1/4”-14 x 5/8” Self tapping
screws (as required)
1/4”-20 x 5/8”
Carriage bolts (as required)
Intermediate I section
18”
or
21”
Bottom corner bracket warning labels
(2) 5/16”-18 x 3/4”
Carriage bolts
1/4”-20 x 7/8” Self
drilling screws (as required)
5/16”-18 Hex nuts
(as required)
Bottom weather seal
Bottom section
Section side
view illustration
Removing an Existing Door
3/8”- 16 Hex nuts
(as required)
(2) 1/4” - 20 Hex
nuts (lift handles)
1/4”- 20 Flanged
hex nuts (as required)
IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE
ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.
WARNING
A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE
SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR
SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS,
RELEASE THE SPRING TENSION.
5/16” x 2” Hex head lag screws (as required)
(2) #8 x 1-5/8” Self tapping screws (step plate)
For detailed information see supplemental instructions “Removing an Existing Door / Preparing the Opening”. These instructions are not supplied with the door, but are available at no
charge from Wayne Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope,
OH., 44660, or at www.Wayne-Dalton.com.
1/4” - 20 x 2-1/2” Carriage bolts (lift handles)
Preparing the Opening
1/4” - 20 x 2-3/4” Carriage bolts (as required)
IMPORTANT: IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A
NEW DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING.
To ensure secure mounting of track brackets, side and center brackets, or steel angles to
new or retro-fit construction, it is recommended to follow the procedures outlined in DASMA
technical data sheets #156, #161 and #164 at www.dasma.com.
The inside perimeter of your garage door opening should be framed with wood jamb
and header material. The jambs and header must be securely fastened to sound framing
members. It is recommended that 2” x 6” lumber be used. The jambs must be plumb and
the header level. The jambs should extend a minimum of 12” (305 mm) above the top of
the opening for TorqueMaster® counterbalance systems. For low headroom applications, the
jambs should extend to the ceiling height. Minimum side clearance required, from the opening to the wall, is 3-1/2” (89 mm).
IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD
FOUND NOT TO BE SOUND, MUST BE REPLACED.
For TorqueMaster® counterbalance systems, a suitable mounting surface (2” x 6”) must be
firmly attached to the wall, above the header at the center of the opening.
NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting the lumber. Do not
attach the mounting surface with nails.
WEATHERSTRIPS (MAY NOT BE INCLUDED):
Depending on the size of your door, you may have to cut or trim the weatherstrips (if necessary) to properly fit into the header and jambs.
NOTE: If nailing product at 40°F or below, pre-drilling is required.
NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.
For the header, align the weatherstrip 1/8” to 1/4” inside the header edge, and temporarily
secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the
weatherstrip up tight against the temporarily attached weatherstrip in the header and 1/8”
to 1/4” inside the jamb edge. Temporarily secure the weatherstrip with equally spaced nails.
Repeat for other side. This will keep the bottom section from falling out of the opening during
installation. Equally space nails approximately 12” to 18” apart.
Headroom requirement: Headroom is defined as the space needed above the top of the
door for tracks, springs, etc. to allow the door to open properly. If the door is to be motor
operated, 2-1/2” (64 mm) of additional headroom is required.
Backroom requirement: Backroom is defined as the distance needed from the opening
back into the garage to allow the door to open fully.
BACKROOM REQUIREMENTS
Door Section Identification
Door Section Identification
Door Height
Bottom
Lock (second)
Intermediate
I (third)
Intermediate
II (fourth)
Top
6’0”
18”
18”
18”
N/A
18”
6’3”
21”
18”
18”
N/A
18”
6’6”
21”
18”
18”
N/A
21”
6’9”
21”
21”
21”
N/A
18”
7’0”
21”
21”
21”
N/A
21”
7’6”
18”
18”
18”
18”
18”
7’9”
21”
18”
18”
18”
18”
8’0”
21”
18”
18”
18”
21”
When installing your door you must use sections of the appropriate height in the right stacking order. What section heights you need to use in what order depends on the height of your
door.
Unless your door is five sections in height, you will not receive an Intermediate II section.
The BOTTOM SECTION can be identified by the factory attached bottom astragal, the factory
attached bottom corner brackets, and by the bottom corner bracket warning labels on each
end stile.
The INTERMEDIATE I SECTION may have a warning label attached to either right or left
hand end stile of the section. This section is always the 3rd section from the bottom of the
door.
3
DOOR HEIGHT
TRACK
MANUAL LIFT
MOTOR OPERATED
6’0” to 7’0”
12”,14” Radius
102” (2591 mm)
125” (3175 mm)
DOOR HEIGHT
TRACK
MANUAL LIFT
MOTOR OPERATED
7’1” to 8’0”
12”,14” Radius
114” (2896 mm)
137” (3480 mm)
HEADROOM REQUIREMENTS
TRACK TYPE
SPACE NEEDED
14” Radius track
12-1/2” (318 mm)
12” Radius track
10-1/2” (267 mm)
6” Low Headroom
6” (152 mm)
Suitable mounting surface
2”x 6” lumber minimum
Headroom
Min. Side
room
Clearance
is 3-1/2”
Header board 2”x 6”
lumber preferred
Min. Side
room
Clearance
is 3-1/2”
er
ead
lh
eve
Bac
kro
Nail
om
L
ips Finished
Door
Height
str
her
at
We
Plumb
jambs
ed
ish
Fin width
r
Doo
bs
Jam
Jamb
Weatherstrips
1/8” to 1/4”
4
PARTS BREAKDOWN
NOTE: The illustrations shown on this page are general
representations of the door parts. Each specific door
models may have unique variations.
A1.
J6.
J4.
J9.
C1.
J1.
I2.
G1.
F2.
G2.
F3.
J2.
F1.
J8.
H2.
E1.
J5.
J3.
K1.
H1.
J7.
F2.
C1.
B1.
F3.
E2.
F1.
I1.
E3.
I4.
A1.
E4.
L1.
D4.
D3.
B1.
D2.
K1.
C2.
D1.
C1.
I3.
L1.
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 Cable Drum Assembly
J6. Right Hand Cable Drum Assembly
J7. Idler bracket (Single Spring Only)
J8. Left Hand Drum Wrap (Optional)
J9. Right Hand Drum Wrap (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
A. FLAG ANGLES:
A1. Left Hand And Right Hand Flag Angles
B. JAMB BRACKETS (AS REQUIRED):
B1. Left Hand And Right Hand Jamb Brackets
C. TRACK ROLLERS:
C1. Short Stem Track Rollers
C2. Long Stem Track Rollers
D. GRADUATED END HINGES:
D1. Single Graduated End Hinges (S.E.H.), 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)
5
1st hole set
2nd hole set
3rd hole set
Top of track
INSTALLATION
1
1/4”- 20 x 5/8”
Carriage bolt
Vertical Tracks
NOTE: If you have a wall angle track assembly, skip this step.
NOTE: Refer to Door Section Identification / Parts Breakdown, to determine if you have vertical tracks.
Vertical tracks may or may not have to be cut to the proper length, prior to installing.
IMPORTANT: VERTICAL TRACKS ARE NOT REQUIRED TO BE CUT DOWN IF YOU HAVE DOOR
HEIGHTS 7’-0” OR 8’-0”.
Determine the radius of your horizontal track.
Stamped
radius
3
Jamb bracket
in place
Jamb
bracket
1/4”- 20
Flange hex nut
Tools Required: Power drill, 5/16” Drill bit, Hacksaw, Tape measure, Safety
glasses, Leather gloves
12”
Vertical track
Slot pattern
Before installing your door, be certain that you have read and followed all of the instructions covered in the pre-installation section of this manual. Failure to do so may result in an
improperly installed door.
NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.
Flag Angles
Tools Required: Tape measure, Safety glasses, Leather gloves
NOTE: If you have a wall angle track assembly, skip this step. Refer to Package Contents /
Parts Breakdown, to determine if you have flag angles.
NOTE: Flag angles are right and left handed.
Hand tighten the left hand flag angle to the left hand vertical track using (2) 1/4” - 20 x 5/8”
carriage bolts and (2) 1/4” - 20 flange hex nuts. Repeat for other side. Flange nuts will be
secured after flag angle spacing is completed in step, Top Section.
Horizontal
track
Flag angle
Refer to the vertical track cutting chart to determine the length needed to be cut off at the top
of the vertical tracks. Using this measurement, measure and cut the vertical track off at the
top, as shown. Remove any burrs from the cut edge of vertical track.
(2) 1/4”-20
Flange hex nuts
Vertical Track Cutting Chart
Horizontal Track Radius
Vertical Track Cut Length
10” Or 12” Radius
Door Height Minus 10”
14” Radius
Door Height Minus 8”
Vertical
track
Measure and cut
Top of
track
Vertical
track
Now, two holes must be drilled into the top of the cut vertical track. Using the illustration
shown below, mark and drill the hole locations using a 5/16” drill bit. Once the holes have
been drilled, remove any burrs from the drilled holes. Repeat the same process for the other
vertical track.
5/8”
1/2”
Measure and drill
5/8”
5/16” Holes
2
Graduated Hinge Attachment
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Level, Safety
glasses, Leather gloves
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.
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.
Vertical
track
4
(2) 1/4”- 20 x 5/8”
Carriage bolts
Jamb Brackets
Tools Required: Tape measure, Safety glasses, Leather gloves
NOTE: If you have a wall angle track assembly, skip this step. Refer to Package Contents /
Parts Breakdown, to determine if you have flag angles.
NOTE: The bottom jamb bracket is always the shortest bracket or the lowest number marked
on the jamb bracket. The center jamb bracket is the next tallest or the next higher number
marked on the jamb bracket. If three jamb brackets per side are included with your door, you
will have received a top jamb bracket, which is the tallest or the highest number marked on
the jamb bracket.
To attach the bottom jamb bracket, locate lower slot pattern of the 1st hole set on the vertical
track. Align the slot in the jamb bracket with the lower slot pattern. Loosely, secure jamb
bracket using (1) 1/4” - 20 x 5/8” carriage bolt and (1) 1/4” - 20 flange hex nut. Repeat for
other side.
Place the center jamb bracket over the slot pattern that is centered between the bottom jamb
bracket and flag angle of the 2nd hole set. Loosely, secure jamb bracket using (1) 1/4” - 20 x
5/8” carriage bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.
If a top jamb bracket was included, loosely secure it to vertical track using the slot pattern
in the 3rd hole set and (1) 1/4” - 20 x 5/8” carriage bolt and (1) 1/4” - 20 flange hex nut.
Repeat the same process for the other vertical track.
6
Short stem
track roller
#1 Graduated
end hinge
Top section
#1Center hinge(s)
End cap
Upper center
hole
Hole
#2 Graduated end hinge
(short stem track roller
inserted into tube
furthest from section)
Lower
hinge leaf
Top fixture slide
Top fixture base
(4) 1/4”-20 x 11/16”
Self drilling screws
1/4”-14 x 5/8” Self tapping
screw locations
1/4”-20 Flange
hex nut
Center stile(s)
End stile
End stile
Short stem track roller
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Level, Safety
glasses, Leather gloves
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 graduated 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.
4 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
WARNING
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.
5 Section High Door
Left hand
cable drum
assembly
1/4”-20 x 7/8” Self drilling
screws
Strut installation
for top section
Strut installation
for other sections
Graduated end hinges
Center hinge(s)
6
tion
sec
B
Bottom
weather seal
Counterbalance
lift cable loop
Strut
Strut installation at top of top section
m
otto
End cap
1/4”-20 x 7/8” Self drilling
Typical graduated
screws
lower hinge leaf
Strut
Tools Required: Power Drill, 7/16” Socket driver, Tape measure, Level, Safety
glasses, Leather gloves
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.
Strut Schedule
Door Width
Cable Drum Assemblies and Track Rollers
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 supplied 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.
Strut (U-Shaped)
5
7
Strut installation for
other sections
(2) 1/4” - 20 x 11/16”
Self drilling screws
Milford pin
Top Fixtures
Short stem track roller
Tools Required: Power drill, 7/16” Socket driver, Step ladder, Safety glasses,
Leather gloves
Bottom corner
bracket
Roller spacer
Starting on the left hand side, align the upper-center hole of top fixture base with the hole
in the end stile of the top section or below strut (if applicable) and even with the edge of the
top section, as shown. Secure the top fixture to the top section using (4) 1/4” - 20 x 11/16”
self drilling screws. The top fixture slide will be tightened and adjusted later, in step, Adjusting
Top Fixture. Insert short stem track roller into top fixture slide. Repeat same process for other
right hand 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 1/4” - 20 flange hex nuts.
8
(1) 1/4” - 20 x 5/8”
Tamper resistant screw
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
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
7
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.
Bottom
Bottom
section
section
outside
inside
Outside of
lock section
Outside
step plate
(2) 1/4”-20 Nuts
10
Bottom section
Wooden shims (If necessary)
(2) 7/16”
Diameter holes
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.
Center
(2) 9/32”
Outside
Inside lift
(2) Spacers
stile
Diameter holes
lift handle
handle
Outside
of lock
section
4”
(2) 1/4”-20
Hex Nuts
11
Vertical Tracks
Tools Required: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure,
Level, Step ladder, Safety glasses, Leather gloves
IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION
OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION
ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO
DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.
IMPORTANT: THE TOPS OF THE VERTICAL 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 counterbalance lift cable is located between the track rollers and the door jamb. Drill 3/16” pilot
holes into the door jamb for the lag screws.
Loosely fasten jamb brackets and flag angle to the jamb using 5/16” x 2” lag screws. Tighten
lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing,
between the bottom section and vertical track. Hang counterbalance lift cable over flag angle.
Repeat same process for other side.
Tools Required: Power Drill, 9/32”/1/2” Drill bits, 1/4” Wrench, Tape measure,
Phillips head screwdriver, Level, Safety glasses, Leather gloves
Inside
of lock
section
Tools Required: Tape measure, Level, Wooden shims (if necessary), Safety
glasses, Leather gloves
Level
Lift Handle
9
Bottom Section
Weather seal (If applicable)
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.
Inside of
Outside of
Center stile
bottom
bottom
(2) 7/32”
section
section
Diameter holes
Inside
step
Outside
plate
step plate
(2) #8 x 1-5/8” Self
tapping screws
Outside of
bottom
section
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.
(2) 1/4”-20 x 2-3/4”
Carriage bolts
Inside
step
plate
Bottom
section inside
(2) 1/4”-20 x 2-3/4”
Carriage bolts
20” Minimum to
30” Maximum
Outside
step plate
(2) 5/16” Dia.
drilled holes
Inside
step
plate
6” Max.
mounting
height
Outside lift
handle
(2) 1/2”
Diameter holes
(2) 1/4”-20 x 2-1/2”
Carriage bolts
8
Flag angle
Jamb
bracket
Flag angle lag screw
locations
Bottom
section
12
Door width
+ 3-3/8” to 3-1/2”
2” Vertical track
spacing (3/8” to 5/8”)
Track
rollers
Vertical track
assembly
Tools Required: Power drill, 7/16” Socket driver, 7/16” Wrench, Step ladder,
Tape measure, Safety glasses, Leather gloves
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 OPERATION.
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.
5/16” x 2”
Lag screws
Bottom
section
Top Section
13
Flag angle
Nail
Track roller
Floor
Top section
1-11/16”
to 1-3/4”
Stacking Sections
Tools Required: Power drill, 7/16” Socket driver, Tape measure, Level, Step ladder, Safety glasses, Leather gloves
Flag
angle
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
Vertical track
against track rollers
14
Horizontal Tracks
Tools Required: Ratchet wrench, 9/16” Socket, 9/16” Wrench, Level, Step ladder,
Tape measure, Safety glasses, Leather gloves
WARNING
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.
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 5/8” carriage 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.
Lock section
3/8”-16 x 3/4”
Hex head bolt
Horizontal track
Vertical
tracks
1/4”-20
Flange hex nuts
Horizontal
track angle
Flag angle
upper slot
Center
hinge(s)
3/8”-16
Hex nut
1/4”-20 x 5/8”
Carriage bolts
1/4”-20 x 7/8” Self drilling screw locations
Left graduated end hinge
with short stem track roller
Flag angle
Right graduated end hinge
with short stem track roller
15
Adjusting Top Fixtures
Tools Required: 7/16” Wrench, Step ladder, Tape measure, Safety glasses,
Leather gloves
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 1/4” - 20 flange hex
nut to secure the top fixture slide to the top fixture base. Repeat for other side.
9
Right hand
drum wrap
Top s
e
Short stem track
roller
ction
Left hand
drum wrap
1/4”-20
Flange hex nut
Horizontal track
Top fixture slide
16
TorqueMaster® Spring Tube
Tools Required: Safety glasses, Leather gloves
TorqueMaster® spring tube
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.
Label
TorqueMaster®
spring tube
TorqueMaster®
spring tube
Shipping
boot
Label
Shipping boot
17
19
Tools Required: Tape measure, Step ladder, Safety glasses, Leather gloves
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 TorqueMaster® 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 ENGAGED 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 TorqueMaster® 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.
Counterbalance lift cable
Winding shaft
Cable drum
1-1/2 wraps
Cam peak
straight
Grooves
Shipping
boot
Label
Cable Drum Assemblies
Center Bracket Bushing Assembly
Tools Required: Safety glasses, Leather gloves
Being cam shaped, the center bushing only fits one way. Slide the center bracket bushing assembly towards the center of the TorqueMaster® spring tube, from the right side, as shown.
Center bracket
TorqueMaster®
spring tube
Center bushing
Cam peak
Winding
shaft
5”
Center bracket bushing assembly
18
TorqueMaster® spring
tube assembly
Drum Wraps (Optional)
Tools Required: Safety glasses, Leather gloves
Round notch
NOTE: If you don’t have drum wraps (optional), then skip this step. Refer to Package Contents / 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.
Left hand
cable drum
Snap
Snaps
Groove
Idler
bracket
Idler
bracket
Snap
10
Flag
angle
Splines
Right cable
drum
Left hand
cable drum
TorqueMaster® spring tube assembly
Counterbalance
lift cable
1-1/2 wraps
Groove
Groove
Round
notch
Left hand
cable drum
bearing
Left
hand
cable
drum
Idler bracket
Flag
angle
Left hand
cable drum
Idler
bracket
Left hand
cable drum
bearing
Tools Required: Power drill, 3/16” Drill bit, 7/16” Socket driver, 1/2” Wrench,
Tape measure, Step ladder, Safety glasses, Leather gloves
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 2” 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 2” 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.
Left
hand
cable
drum
5/16”
Washer
5/16” Hex
nut
5/16” x 2”
Lag screw
End Brackets
20
TorqueMaster®
spring tube
assembly
Left hand
cable drum
Flag angle
Flag angle
5/16” -18 x 3/4”
Carriage bolt
Flag angle
TorqueMaster®
spring tube
assembly
Idler bracket
Idler bracket
Left hand
cable drum
bearing
Flag angle
21
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
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 2” lag
screws.
Grooves
Center bracket
bushing assembly
Winding
shaft
TorqueMaster®
spring tube
(2) 5/16” x 2”
Lag screws
Splines
Disconnect cable
guide hole
Flag angle
Warning tag
Ratchet wheel
(teeth pointing
upwards)
5/16” Hex nut
5/16” x 2”
Lag screw
5/16” -18 x 3/4”
Carriage bolt
Black tooth
Tools Required: Vice Clamps, Step ladder, Safety glasses, Leather gloves
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).
Right hand end bracket
Right hand
end bracket
22
Securing Door For Winding Spring(s)
WARNING
5/16”
Washer
FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW
DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.
Flag angle
11
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.
Vice clamps above third track
roller on both sides of door
Bottom section
Vice clamps attached to inner
and outer rail of vertical track
23
Lift Cable Adjustments
Tools Required: Locking pliers, Flat tip screwdriver, Step ladder, Tape measure,
Pliers / Wire cutters, Safety glasses, Leather gloves
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 TorqueMaster® 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.
First and
second grooves
WINDING SPRING TURN CHART
DOOR HEIGHT
Cam peak
pointing straight up
Cut cable here
Set screw
TorqueMaster®
spring tube
6”
Insert
cable here
24
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
End bracket
Marks
Counterbalance
lift cable
Winding Spring(s)
5/8”
Socket
Winding
shaft
Tools Required: Ratchet wrench, 5/8” Socket, 3” Socket extension, Pliers / Wire
cutters, Flat tip screwdriver, Step ladder, Tape measure, Safety glasses, Leather
gloves
Black tooth
on ratchet
wheel
Mark the number of
spring turns onto the
end bracket warning tag
WARNING
WINDING TORSION SPRING(S) IS AN EXTREMELY DANGEROUS PROCEDURE AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM
WARNING
IT IS RECOMMENDED THAT LEATHER GLOVES BE WORN WHILE WINDING
SPRINGS. FAILURE TO WEAR GLOVES MAY CAUSE INJURY TO HANDS.
25
Ratchet
wrench
Pawl knob in
lower position
Pawl knob in
upper position
3”
Extension
Securing Drum Wraps (Optional)
Tools Required: Step ladder, Safety glasses, Leather gloves
NOTE: If you don’t have drum wraps (optional), then skip this step. Refer to Package Contents / 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.
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.
12
Last rib Drum wrap
3 catches
Cable
drum
3rd rib
3rd rib
Horizontal tracks
Counterbalance
lift cable. Pull to
clear latch
26
Hinged latch
Re-engage
hinged latch
Rear Back Hangs
Vice clamp
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
Vice clamp
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.
2nd Track roller
WARNING
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 2” 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.
Sound framing
members
WARNING
EXCEEDING THE RECOMMENDED LISTED DOOR WEIGHT LIMITATIONS OF
SPECIFIC GAUGE PERFORATED ANGLES MAY RESULT IN DOOR FALLING
WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.
Perforated angle bolted
using (2) 5/16” x 2” hex
head lag screws to
ceiling member and
parallel to door
WARNING
VERIFY PERFORATED BACK HANG ANGLE LOAD RATINGS WITH BACK
HANG ANGLE SUPPLIER.
Horizontal
track
(3) 5/16” Bolts and nuts
Perforated Angle Gauge Weight Limitations:
Perforated Angle Gauge
Door Weight
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.
5/16”-18 x 1-1/4”
Hex bolt must extend into the
track to serve as a roller stop
Perforated angle
NOTE: If an opener is installed, position horizontal tracks one hole above level when securing
it to the rear back hangs.
WARNING
Sound framing
members
KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4” TO 7/8” MAXIMUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN
SEVERE OR FATAL INJURY.
IMPORTANT: DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR
BACK HANGS THAT CANTILEVERS 4” OR MORE BEYOND A SOUND FRAMING MEMBER.
NOTE: If rear back hangs are to be installed over drywall, use (2) 5/16” x 2” hex head lag
screws and make sure lag screws engage into solid structural lumber.
NOTE: 26” angle must be attached to sound framing members and nails should not be
used.
Now, permanently attach the weatherstrips on both door jambs and header. The weatherstrips were temporarily attached in Preparing the Opening, in the pre-installation section of
this manual.
NOTE: When permanently attaching the weatherstrips to the jambs, avoid pushing the weatherstrips too tightly against the face of door.
(3) 5/16”
Bolts and nuts
Horizontal
track
Perforated angle
5/16”-18 x 1-1/4”
Hex bolt must extend into the
track to serve as a roller stop
13
Perforated angle bolted
using (2) 5/16” x 2” hex
head lag screws to
ceiling member and
parallel to door
3/4” To 7/8”
27
Door edges
Horizontal tracks
3/4” To 7/8”
Balancing Door
Tools Required: Ratchet wrench, Socket: 5/8”, Wrench: 5/8”, 3” Socket extension, (2) Vice clamps, Step ladder, Tape measure, Safety glasses, Leather gloves
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 adjustments 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.
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
Pawl knob in
lower position
Winding
shaft
3”
extension
Pawl
Pawl
Pawl knob in
upper position
End bracket
Ratchet wheel
5/8” Socket
14
Optional Installation
IMPORTANT: THE DRAWBAR OPERATOR FORCE SETTINGS MUST BE ADJUSTED ACCORDING TO THE MANUFACTURER’S INSTRUCTIONS. SOME LIGHTER WEIGHT DOORS ARE
DESIGNED TO OPERATE WITH A SINGLE COUNTERBALANCE SPRING. IF THAT COUNTERBALANCE SPRING BREAKS AND THE DRAWBAR OPERATOR’S FORCE SETTINGS ARE NOT
ADJUSTED ACCORDING TO THE MANUFACTURER’S SPECIFICATIONS, THE DRAWBAR
OPERATOR MAY THEN HAVE THE CAPABILITY OF LIFTING THE DOOR TO THE OPEN POSITION, DESPITE THE BROKEN COUNTERBALANCE SPRING. THIS SCENARIO WILL CAUSE
THE COUNTERBALANCE LIFT CABLES TO GO SLACK AND ENGAGE THE TORQUEMASTER®
PLUS SAFETY SYSTEM. IF A PERSON IS UNAWARE OF THE SLACK COUNTERBALANCE LIFT
CABLES AND THE ENGAGED TORQUEMASTER® PLUS SAFETY SYSTEM AND ACTIVATES THE
MISADJUSTED DRAWBAR OPERATOR, DAMAGE WILL LIKELY OCCUR TO THE DOOR AND
DRAWBAR OPERATOR. THE POTENTIAL ALSO EXISTS THAT THE PERSON ACTIVATING THE
DRAWBAR OPERATOR UNDER THIS SCENARIO COULD BE SEVERELY INJURED.
Ratchet
pawl
Side
view
Cable
drum
Drum
pawl
Drum
pawl
No space between drum pawl and
cable drum indicates engagement
WARNING
Cable
drum
Space between drum pawl and cable
drum indicates non-engagement
Below
view
READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO RESET THE TORQUEMASTER® PLUS SYSTEM. IF IN QUESTION ABOUT ANY
OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A
QUALIFIED DOOR SYSTEMS TECHNICIAN RESET THE SYSTEM.
Drum wrap
(if applicable)
WARNING
Ratchet
wrench
TO AVOID SEVERE OR FATAL INJURY, DO NOT STAND OR WALK UNDER
A MOVING DOOR, OR PERMIT ANYONE TO STAND OR WALK UNDER AN
ELECTRICALLY OPERATED DOOR.
Pawl knob in
lower position
This door is equipped with a TorqueMaster® plus system, a safety feature which prevents
the door from rapidly descending in case of spring failure or forceful manual operation. If the
system engages with the door in the open position, personal items that are left unattended in
the garage or home are at risk to theft. To ensure the safekeeping of these items, close the
garage door.
Typical signs of an engaged system.
Single spring system: Visually inspect the TorqueMaster® Plus right hand end bracket to
confirm that the system has engaged (see illustration). If the system is engaged, then the
door will not close. If the drawbar operator force settings were properly set during the initial
installation, the door will not open. If the drawbar operator can physically overcome the
weight of the door and lift it to the open position, then the counterbalance lift cables will be
slack. If the system is engaged, DO NOT attempt to make the repairs. Instead, have a trained
door system technician make the necessary repairs to counterbalance lift cables, spring
assemblies and other hardware.
Double spring system: Visually inspect the TorqueMaster® Plus end brackets to confirm
that the system has engaged (see illustration). Door makes a distinct “clicking” noise upon
being opened. If the system is engaged, carefully follow the reset instructions below or refer
to the reset tag (attached to right hand end bracket) to reset the TorqueMaster® Plus system.
Resetting an engaged TorqueMaster® Plus double spring system only:
1. First, locate and visually inspect the TorqueMaster® plus end bracket(s) to confirm that the
system has engaged (see illustration).
2. With the door in the fully closed position, place vice clamps onto both vertical tracks just
above the third track roller. Disengage the drawbar operator (if installed) by pulling or placing
the emergency disconnect in the manually operated position.
3. With assistance, carefully remove vice clamps and raise the door to the fully open position.
4. Place vice clamps onto both vertical tracks just below the bottom track roller on both sides.
5. Now is a good time to remove vehicles or personal items from garage to provide clear
access to end brackets.
6. For single spring applications: Flip the ratchet pawl knob on the right hand end bracket
to the upper position. For double spring applications: Flip the ratchet pawl knob on both
end brackets to the upper position (see illustration).
7. Raise door 2”-3” and then lower door. Repeat this process until the system resets (see
disengaged system illustrations).
IMPORTANT: BE PREPARED TO SUPPORT THE TOTAL WEIGHT OF THE DOOR.
8. Cautiously remove the vice clamps from the vertical tracks. With assistance lower door.
Checking springs for tension:
9. Starting on the right hand side, place a ratchet wrench, 5/8” socket and a 3” extension
on the TorqueMaster® Plus winding shaft (see illustration). Ensure ratchet is set so that it will
tighten counter clockwise on the right hand side, and clockwise on the left hand side. If tension is present, remove the ratchet and check the left hand side. If spring(s) have tension, the
door will need to be balanced; refer to step, Balancing Door, to do this. If no spring tension is
present, contact a qualified trained door system technician to replace the spring(s).
IMPORTANT: TO AVOID POSSIBLE INJURY, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN
MAKE ADJUSTMENTS/ REPAIRS TO COUNTERBALANCE LIFT CABLES, SPRING ASSEMBLIES
AND OTHER HARDWARE.
3”
extension
Winding
shaft
Pawl
Pawl
End bracket
Ratchet wheel
TorqueMaster® Plus
reset instructions tag
Pawl knob in
upper position
5/8” socket
Inside Lock
Install the inside lock on the second section of the door. Secure the lock to the section with
(4) 1/4” - 20 x 11/16” self drilling screws. Square the lock assembly with the door section,
and align with the square hole in the vertical track. The inside lock should be spaced approximately 1/8” away from the section edge.
IMPORTANT: INSIDE LOCK(S) MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR.
Square hole in
vertical track
Second section
(4) 1/4”-20 x 11/16”
Self drilling screws
Side lock
1/8”
End stile
Pull Down Rope
WARNING
DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH OPERATORS.
CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR
FATAL INJURY.
Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the
right or left side of jamb. Drill 1/8” pilot hole for no. 6 screw eye. Tie the pull down rope to the
no. 6 screw eye and to the bottom corner bracket, as shown.
15
No. 6 Screw eye
Typical bottom
corner bracket
48” to 50”
From floor
Pull down
rope
Pull
down
rope
16
Maintenance
or drawbar operator bracket supplied with the door. To avoid possible damage to your door,
Wayne Dalton recommends reinforcing the top section on models 8000, 8100, 8200 and
9100 doors with a strut (may or may not be supplied). The installation of the drawbar operator must be according to manufacturer’s instructions and force settings must be adjusted
properly. Refer to the owner’s manual supplied with your drawbar operator for complete
details on installation, operation, maintenance and testing of the operator.
MAINTAINING YOUR GARAGE DOOR:
Before you begin, read all warning labels affixed to the door and the installation instructions 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.
Cleaning Your Garage Door
IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR!
While factory-applied finishes on garage doors are durable, it is desirable to clean them on
a routine basis. Some discoloration of the finish may occur when a door has been exposed
to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of
direct exposure to sunlight.
Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, a periodic washing of the garage door is recommended.
THE FOLLOWING CLEANING SOLUTION IS RECOMMENDED:
A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate)
dissolved into five gallons of warm water will aid in the removal of most dirt.
NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended
for use in general cleaning of garage doors.
NOTE: Be sure to clean behind weatherstrips on both sides and top of door.
WARNING
CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.
GLASS CLEANING INSTRUCTIONS
Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse
thoroughly.
ACRYLIC CLEANING INSTRUCTIONS
Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare
hands to feel and dislodge any caked on particles. A soft, grit-free cloth, sponge or chamois
may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic
glazing. Dry glazing with a clean damp chamois.
NOTE: Do not use any window cleaning fluids, scouring compounds, gritty cloths or solventbased cleaners of any kind.
GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACKETS, AND OTHER HARDWARE ATTACHED TO THE SPRINGS ARE UNDER
EXTREME TENSION, AND IF HANDLED IMPROPERLY, CAN CAUSE SEVERE
OR FATAL INJURY. ONLY A TRAINED DOOR SYSTEMS TECHNICIAN
SHOULD ADJUST THEM, BY CAREFULLY FOLLOWING THE MANUFACTURER’S INSTRUCTIONS.
WARNING
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.
Painting Your Garage Door
Refer to Instruction Insert “Field Painting and Finishing Fiberglass or Steel Door Sections”.
Maintaining The Finish
On Your Garage Door
TorqueMaster® Plus Springs: Pawl knob(s) (located on the TorqueMaster® end brackets above
the door) should be engaged to prevent the door from rapidly descending in case of spring
failure or forceful manual operation.
Torsion Springs: The torsion springs (located above the door) should only be adjusted by a
trained door systems technician. DO NOT attempt to repair or adjust torsion springs yourself.
Extension Springs: A restraining cable or other device should be installed on the extension
spring (located above the horizontal tracks) to help contain the spring if it breaks.
2. Door Balance: Periodically test the balance of your door. If you have a garage door
drawbar operator, use the release mechanism so you can operate the door by hand when doing this test. Start with the door in the fully closed position. Lift the door to check its balance.
Adjust TorqueMaster® or Extension spring(s), if door lifts by itself (hard to pull down) or if
door is difficult to lift (easy to pull down). DO NOT attempt to repair or adjust Torsion Springs
yourself. To adjust TorqueMaster® or Extension spring(s), refer to your installation instructions
and owner’s manual. If in question about any of the procedures, do not perform the work.
Instead, have it adjusted by a trained door systems technician.
3. Lubrication: The door should open and close smoothly. Ensure the door track rollers
are rotating freely when opening and closing the door. If track rollers do not rotate freely,
clean the door tracks, removing dirt and any foreign substances. Clean and lubricate (use
a non-silicon based lubricant) graduated end hinges, center hinge(s), steel track rollers,
bearings and torsion spring(s) (torsion spring coil surfaces). DO NOT lubricate plastic idler
bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difficult use
a graphite dust to lubricate.
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
17
Warranty
Limited Warranty
Models 8000, 8100, 8200
Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants 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 defective during
the applicable warranty period. Any labor charges are excluded and will be the responsibility of the purchaser.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty is made to the original purchaser
of the Product only, and is not transferable or assignable. This warranty applies only to Product installed in a residential or other non-commercial application. It does not
cover any Product installed in commercial or industrial building applications. This warranty does not apply to any unauthorized alteration or repair of the Product, or to
any Product or component which has been damaged or deteriorated due to misuse, neglect, accident, failure to provide necessary maintenance, normal wear and tear,
acts of God, or any other cause beyond the reasonable control of Seller or as a result of having been exposed to toxic or abrasive environments, including blowing sand,
salt water, salt spray and toxic chemicals and fumes.
ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, ARE LIMITED IN TIME TO THE APPLICABLE WARRANTY PERIOD REFLECTED ABOVE. NO WARRANTIES, WHETHER EXPRESS OR IMPLIED,
WILL APPLY AFTER THE LIMITED WARRANTY PERIOD HAS EXPIRED. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation
may not apply to you.
IN NO EVENT SHALL SELLER BE RESPONSIBLE FOR, OR LIABLE TO ANYONE FOR, SPECIAL, INDIRECT, COLLATERAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL
DAMAGES, even if Seller has been advised of the possibility of such damages. Such excluded damages include, but are not limited to, loss of use, cost of any substitute
product, or other similar indirect financial loss. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or
exclusion may not apply to you.
Claims under this warranty must be made promptly after discovery, within the applicable warranty period, and in writing to the authorized distributor or installer
whose name and address appear below. The purchaser must allow Seller a reasonable opportunity to inspect any Product claimed to be defective prior to removal or
any alteration of its condition. Proof of the purchase and/or installation date, and identification as the original purchaser, may be required. There are no established
informal dispute resolution procedures of the type described in the Magnuson-Moss Warranty Act.
•SELLER:
_______________________________________________________________________
•SELLER’S ADDRESS: _______________________________________________________________________
_______________________________________________________________________
18
Thank you for your purchase.
PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE
Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1)
and follow the prompts to contact the appropriate customer service agent. They will be happy
to handle any questions that you may have.
AFTER INSTALLATION IS COMPLETE, FASTEN THIS
MANUAL NEAR GARAGE DOOR FOR EASY REFERENCE.
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