Wayne Dalton TorqueMaster Plus 8000, 8100, 8200 garage door Installation Instructions

Below you will find brief information for garage door TorqueMaster Plus 8000, garage door TorqueMaster Plus 8100, garage door TorqueMaster Plus 8200. These garage doors are designed for residential use and are equipped with TorqueMaster Plus spring system for easy operation. The instructions cover pre-installation, installation, and maintenance instructions.

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Pre-Installation 2

Important Safety Instructions 2

Tools Required

Package Contents

Door Section Identification

Removing an Existing Door

Preparing the Opening

Parts Breakdown

Installation 6

Optional Installation 15

3

5 Inside Lock

Pull Down Rope

15 Maintenance 17

Cleaning Your Garage Door 17

Painting Your Garage Door

Maintaining The Finish On Your Garage Door

17 Operation And Maintenance 17

Warranty 18

2 PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

If you need assistance, please call 1-866-

569-3799 (press Option 1) and follow the prompts to contact a customer service representative. They will be happy to handle any questions that you may have.

IMPORTANT NOTICES!

To avoid possible injury, read and fully understand 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.

This Installation document is available at no charge from:

Wayne Dalton, a division of Overhead Door Corporation,

P.O. Box 67, Mt. Hope, OH., 44660, Or Online At

www.Wayne-Dalton.com

Part Number 353179 REV5_06/24/2016

Pre-Installation

Important Safety Instructions

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 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.

Avoid installing your new door on windy days. Door could fall during the installation causing severe or fatal injury.

Doors 12’-0” wide and over should be installed by two persons, to avoid possible injury.

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 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 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.

WARNING

PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS,

ENSURE YOU'RE WINDING IN THE PROPER DIRECTION AS STATED IN

THE INSTALLATION INSTRUCTIONS. OTHERWISE, THE SPRING FITTINGS

MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION

AND COULD RESULT IN SEVERE OR FATAL INJURY.

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

LOOKING OUT

Tools Required

Power drill

Drill bits: 1/8”, 3/16”, 9/32”,

7/16”, 1/2”

Ratchet wrench

Socket driver: 7/16”

Sockets: 7/16”, 1/2”, 9/16”,

5/8”

Socket extension: 3”

Phillips head screwdriver

Flat tip screwdriver

Pliers / Wire cutters

Needle nose pliers

Locking pliers

(2) Vice clamps

Wrenches: 7/16”, 1/2”, 9/16”,

5/8”

Hammer

Tape measure

Step ladder

Level

Pencil

Saw horses

Leather gloves

Safety glasses

Package Contents

NOTE: Depending on the door model, some parts listed will not be supplied if not required.

Rear Back Hangs may not be included with your door.

Door sections (as required)

TorqueMaster ® spring tube

Vertical tracks RH/LH

Horizontal tracks RH/LH

Flag angles RH/LH (as required)

GED SID

IEW

Jamb brackets

(as required)

ER NE

ATH VI

Rat che t Pa Left hand end bracket

(as required)

Right hand end bracket

Center bracket bushing assembly

Idler bracket

(single spring only)

Drum wraps

RH/LH (as required)

Cable drum assemblies RH/LH

Graduated hinges (as required)

Bottom corner brackets RH/LH

(2) Top fixture assemblies

Track rollers

(as required)

Strut (U-shaped)

(if included)

Weatherstrips & nails (If included)

Pull down rope (if included)

2

(1) Step plates

(as required)

(1) Step plate

(as required)

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.

(2) Step plates

(as required)

(2) Lift handles &

Spacers

(2) Roller spacers

Warning label

Intermediate I section

(2) 5/16” Washers

3/8”-16 x 3/4” Hex bolts

(as required)

18” or

21”

Bottom corner bracket warning labels

1/4”-14 x 5/8” Self tapping screws (as required)

(2) 5/16”-18 x 3/4”

Carriage bolts

1/4”-20 x 11/16” Self drilling screws

(RED HEAD) (as required)

1/4”- 20 Flanged hex nuts (as required)

1/4”-20 x 11/16”

Self drilling screws (as required)

1/4”-20 x 5/8”

Carriage bolts (as required)

1/4”-20 x 7/8” Self drilling screws (as required)

3/8”- 16 Hex nuts

(as required)

5/16”-18 Hex nuts

(as required)

(2) 1/4” - 20 Hex nuts (lift handles)

5/16” x 2” Hex head lag screws (as required)

(2) #8 x 1-5/8” Self tapping screws (step plate)

1/4” - 20 x 2-1/2” Carriage bolts (lift handles)

1/4” - 20 x 2-3/4” Carriage bolts (as required)

Door Section Identification

Door Height

7’0”

7’6”

7’9”

8’0”

6’0”

6’3”

6’6”

6’9”

Bottom

21”

18”

21”

18”

21”

Door Section Identification

Lock (second)

Intermediate

I (third)

18”

21”

18”

21”

18”

21”

18”

Intermediate

II (fourth)

N/A

18”

Top

21”

18”

21”

18”

21”

18”

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.

3

Bottom weather seal

Bottom section

Section side view illustration

Removing an Existing Door

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.

For detailed information see supplemental instructions “Removing an Existing Door / Preparing the Opening”. These instructions are not supplied with the door, but are available at no charge from Wayne Dalton, a division of Overhead Door Corporation, P.O. Box 67, Mt. Hope,

OH., 44660, or at www.Wayne-Dalton.com.

Preparing the Opening

IMPORTANT: IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A

NEW DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING.

To ensure secure mounting of track brackets, side and center brackets, or steel angles to new or retro-fit construction, it is recommended to follow the procedures outlined in DASMA technical data sheets #156, #161 and #164 at www.dasma.com.

The inside perimeter of your garage door opening should be framed with wood jamb and header material. The jambs and header must be securely fastened to sound framing members. It is recommended that 2” x 6” lumber be used. The jambs must be plumb and the header level. The jambs should extend a minimum of 12” (305 mm) above the top of the opening for 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 HEIGHT TRACK MANUAL LIFT

6’0” to 7’0”

7’1” to 8’0”

12”,14” Radius

102” (2591 mm)

114” (2896 mm)

HEADROOM REQUIREMENTS

TRACK TYPE

14” Radius track

12” Radius track

6” Low Headroom

MOTOR OPERATED

125” (3175 mm)

137” (3480 mm)

SPACE NEEDED

12-1/2” (318 mm)

10-1/2” (267 mm)

6” (152 mm)

Suitable mounting surface

2”x 6” lumber minimum

Header board 2”x 6” lumber preferred

Headroom

Min. Side room

Clearance is 3-1/2”

Backroom

Nail

Min. Side room

Clearance is 3-1/2”

Level header

Weatherstrips

Finished

Door

Height

Plumb jambs

Finished

Door width

Jamb s

Jamb

1/8” to 1/4”

Weatherstrips

4

A1.

PARTS BREAKDOWN

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

J9.

J1.

F2.

J6.

C1.

A1.

J4.

G1.

G2.

J2.

F3.

F1.

J8.

E1.

J3.

J5.

J7.

B1.

F2.

F3.

C1.

F1.

I1.

E2.

E3.

H1.

I4.

E4.

L1.

D4.

D3.

B1.

D2.

D1.

C2.

K1.

C1.

I3.

L1.

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)

I2.

H2.

K1.

5

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

1st hole set 2nd hole set 3rd hole set

Top of track

INSTALLATION

Before installing your door, be certain that you have read and followed all of the instructions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door.

NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.

Vertical Tracks

Tools Required: Power drill, 5/16” Drill bit, Hacksaw, Tape measure, Safety glasses, Leather gloves

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.

12”

Stamped radius

Horizontal track

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

Horizontal Track Radius

Vertical Track Cutting Chart

Vertical Track Cut Length

10” Or 12” Radius

14” Radius

Door Height Minus 10”

Door Height Minus 8”

Measure and cut

Vertical track

Top of 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

5/16” Holes 5/8”

Vertical track

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.

Slot pattern

1/4”- 20

Flange hex nut

Jamb bracket

Vertical track

1/4”- 20 x 5/8”

Carriage bolt

Jamb bracket in place

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.

Flag angle

(2) 1/4”-20

Flange hex nuts

Vertical track

(2) 1/4”- 20 x 5/8”

Carriage bolts

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.

6

Short stem track roller

#1 Graduated end hinge

#1Center hinge(s)

Lower hinge leaf

1/4”-14 x 5/8” Self tapping screw locations

End stile

#2 Graduated end hinge

(short stem track roller inserted into tube furthest from section)

Center stile(s) End stile

Strut (U-Shaped)

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.

Door Width

Strut Schedule

4 Section High Door 5 Section High Door

8’0” – 13’11”

14’0” – 16’0”

16’1” – 18’0”

18’1” – 20’00”

N/A

(1) Strut Top Section

(3) Struts Top, Lock and Bottom

Sections

(4) Struts All Sections

N/A

(2) Struts Top and Bottom

Sections

(3) Struts Top, Intermediate I and Bottom Section

(5) Struts, All Sections

Top section

Hole

Top fixture base

End cap

Upper center hole

Cable Drum Assemblies and Track Rollers

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.

IMPORTANT: IF THE DOOR WILL BE EXPOSED TO A SIGNIFICANT AMOUNT OF ROAD SALT,

PAINT THE BARE GALVANIZED BOTTOM WEATHER STEEL RETAINER TO INHIBIT RUSTING.

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 (3) 1/4” - 20 x

11/16” RED HEAD self drilling screws. Repeat for other side.

IMPORTANT: THE 1/4” - 20 X 11/16” RED HEAD SELF DRILLING SCREWS MUST BE MUST

BE INSTALLED THROUGH THE HOLES OF THE BOTTOM CORNER BRACKETS, AS SHOWN.

NOTE: Cable drum assemblies are marked right and left hand.

WARNING

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.

Left hand cable drum assembly

Strut installation for top section

1/4”-20 x 7/8” Self drilling screws

Graduated end hinges

Center hinge(s)

Strut installation for other sections

Strut

1/4”-20 x 7/8” Self drilling screws Typical graduated lower hinge leaf

Strut

Strut installation at top of top section

Strut installation for other sections

Top Fixtures

Tools Required: Power drill, 7/16” Socket driver, Step ladder, Safety glasses,

Leather gloves

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.

End cap

Bottom section

Bottom weather seal

7

Counterbalance lift cable loop

Milford pin

(3) 1/4”-20 x 11/16”

Self drilling screws

(RED HEAD )

Short stem track roller

Roller spacer

Bottom corner bracket

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 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 section inside

Bottom section outside

6” Max.

mounting height

Inside step plate

(2) 5/16” Dia. drilled holes

Outside step plate

(2) 1/4”-20 x 2-3/4”

Carriage bolts

(2) 1/4”-20 x 2-3/4”

Carriage bolts

Inside step plate

Bottom section inside

(2) 1/4”-20 Nuts

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 bottom section

Center stile

(2) 7/32”

Diameter holes

Inside step plate

Outside of bottom section

Outside step plate

(2) #8 x 1-5/8” Self tapping screws

(2) 7/16”

Diameter holes

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

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.

(2) 9/32”

Diameter holes

Center stile

Inside lift handle

(2) Spacers

Outside lift handle

Inside of lock section

Outside of lock section

4”

(2) 1/4”-20

Hex Nuts

(2) 1/2”

Diameter holes

(2) 1/4”-20 x 2-1/2”

Carriage bolts

Outside lift handle

Outside of lock section

20” Minimum to

30” Maximum

Outside of bottom section

Outside step plate

Bottom Section

Tools Required: Tape measure, Level, Wooden shims (if necessary), Safety glasses, Leather gloves

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.

Weather seal (If applicable)

Level

Bottom section

Wooden shims (If necessary)

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.

8

Flag angle

5/16” x 2”

Lag screws

Jamb bracket

Flag angle lag screw locations

Bottom section

Track rollers

Vertical track assembly

Floor

Track roller

Stacking Sections

Tools Required: Power drill, 7/16” Socket driver, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

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.

Vertical tracks

1/4”-20 x 7/8” Self drilling screw locations

Left graduated end hinge with short stem track roller

Lock section

Center hinge(s)

Right graduated end hinge with short stem track roller

Top Section

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 OPERA-

TION.

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.

Door width

+ 3-3/8” to 3-1/2”

Flag angle

Nail

Top section

1-11/16” to 1-3/4”

Flag angle

Top section

Vertical track against track rollers

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.

Horizontal track

3/8”-16 x 3/4”

Hex head bolt

Flag angle

1/4”-20

Flange hex nuts

Horizontal track angle

Flag angle upper slot

3/8”-16

Hex nut

1/4”-20 x 5/8”

Carriage bolts

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

Label

Shipping boot

Center Bracket Bushing Assembly

Tools Required: Safety glasses, Leather gloves

Shipping boot

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

Center bracket bushing assembly

Drum Wraps (Optional)

Tools Required: 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.

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.

Right hand drum wrap

Short stem track roller

Horizontal track

Top section

1/4”-20

Flange hex nut

TorqueMaster

Spring Tube

Tools Required: Safety glasses, Leather gloves

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

Shipping boot

TorqueMaster

® spring tube

Left hand drum wrap

TorqueMaster

spring tube

Label

Cable Drum Assemblies

Tools Required: Tape measure, Step ladder, Safety glasses, Leather gloves

Shake the TorqueMaster

TorqueMaster ® on top of the flag angles.

® 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

spring tube assembly. Lift the TorqueMaster ® spring tube assembly and rest it

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 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.

Winding shaft

Cam peak straight

Counterbalance lift cable

1-1/2 wraps

Cable drum

Grooves

Winding shaft

5”

TorqueMaster

spring tube assembly

Round notch

Splines

Right cable drum

Flag angle

Snap

Left hand cable drum

Groove

Snaps

Idler bracket

Snap

Idler bracket

Left hand cable drum

10

Groove

Idler bracket

Counterbalance lift cable

1-1/2 wraps

TorqueMaster

spring tube assembly

Groove

Round notch

Flag angle

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

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.

Grooves

Winding shaft

Splines

Disconnect cable guide hole

Flag angle

Warning tag

Left hand cable drum

Flag angle

Left hand cable drum bearing

5/16”

Washer

Idler bracket

5/16” x 2”

Lag screw

5/16” Hex nut

Flag angle

TorqueMaster

® spring tube assembly

Left hand cable drum

5/16” -18 x 3/4”

Carriage bolt

Flag angle

TorqueMaster

® spring tube assembly

Idler bracket

Left hand cable drum bearing

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

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.

Center bracket bushing assembly

TorqueMaster ® spring tube

(2) 5/16” x 2”

Lag screws

Right hand end bracket

Ratchet wheel

(teeth pointing upwards)

Right hand end bracket

5/16” x 2”

Lag screw

5/16”

Washer

5/16” -18 x 3/4”

Carriage bolt

Flag angle

5/16” Hex nut

Securing Door For Winding Spring(s)

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).

WARNING

FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW

DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.

Black tooth

11

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

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

Cam peak pointing straight up

Cut cable here

Set screw

TorqueMaster

® spring tube

6”

Insert cable here

Counterbalance lift cable

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

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.

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.

12

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’-8”

6’-9”

7’-0”

7’-3”

6’-0”

6’-3”

6’-5”

6’-6”

7’-6”

7’-9”

8’-0”

14-1/2

15-1/2

16-1/2

17-1/2

End bracket

Marks

Ratchet wrench

5/8”

Socket

Winding shaft

Black tooth on ratchet wheel

Mark the number of spring turns onto the end bracket warning tag

3”

Extension

Securing Drum Wraps (Optional)

Tools Required: Step ladder, Safety glasses, Leather gloves

Pawl knob in lower position

Pawl knob in upper position

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.

Last rib Drum wrap

Cable drum

3 catches

3rd rib

Counterbalance lift cable. Pull to clear latch

Hinged latch

Re-engage hinged latch

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

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.

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.

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.

WARNING

VERIFY PERFORATED BACK HANG ANGLE LOAD RATINGS WITH BACK

HANG ANGLE SUPPLIER.

Perforated Angle Gauge Weight Limitations:

Perforated Angle Gauge Door Weight

1-1/4” x 1-1/4” x 13 Gauge

1-1/4” x 1-1/4” x 15 Gauge

1-1/4” x 1-1/4” x 16 Gauge

Door Weight Less Than 305 lbs.

Door Weight Less Than 220 lbs.

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.

WARNING

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.

Vice clamp

Horizontal track

5/16”-18 x 1-1/4”

Hex bolt must extend into the track to serve as a roller stop

(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

Horizontal tracks

Sound framing members

2nd Track roller

Vice clamp

Perforated angle bolted using (2) 5/16” x 2” hex head lag screws to ceiling member and parallel to door

(3) 5/16” Bolts and nuts

Perforated angle

Sound framing members

Perforated angle bolted using (2) 5/16” x 2” hex head lag screws to ceiling member and parallel to door

13

3/4” To 7/8”

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

3” extension

Pawl

Winding shaft

Pawl

End bracket

Ratchet wheel

5/8” Socket

Pawl knob in upper position

14 Optional Installation

IMPORTANT: THE DRAWBAR OPERATOR FORCE SETTINGS MUST BE ADJUSTED AC-

CORDING TO THE MANUFACTURER’S INSTRUCTIONS. SOME LIGHTER WEIGHT DOORS ARE

DESIGNED TO OPERATE WITH A SINGLE COUNTERBALANCE SPRING. IF THAT COUNTER-

BALANCE 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 POSI-

TION, 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.

WARNING

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.

WARNING

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.

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.

Side view

Ratchet pawl

Drum pawl

Cable drum

Drum pawl

Cable drum

No space between drum pawl and cable drum indicates engagement

Space between drum pawl and cable drum indicates non-engagement

Below view

Drum wrap

(if applicable)

Ratchet wrench

Winding shaft

Pawl

End bracket

Ratchet wheel

TorqueMaster

Plus reset instructions tag

Inside Lock

3” extension

5/8” socket

End stile

Pull Down Rope

Pawl

Pawl knob in lower position

Pawl knob in upper position

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 UN-

LOCKED POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR.

Square hole in vertical track

Second section

Side lock

(4) 1/4”-20 x 11/16”

Self drilling screws

1/8”

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

48” to 50”

From floor

Pull down rope

No. 6 Screw eye

Pull down rope

Typical bottom corner bracket

16 Maintenance

Cleaning Your Garage Door

IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR!

While factory-applied finishes on garage doors are durable, it is desirable to clean them on a routine basis. Some discoloration of the finish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of direct exposure to sunlight.

Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, a periodic washing of the garage door is recommended.

THE FOLLOWING CLEANING SOLUTION IS RECOMMENDED:

A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into five gallons of warm water will aid in the removal of most dirt.

NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.

NOTE: Be sure to clean behind weatherstrips on both sides and top of door.

CAUTION

NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

the door, along with any struts provided with the door. Always use the drawbar operator and or drawbar operator bracket supplied with the door. To avoid possible damage to your door,

Wayne Dalton recommends reinforcing the top section on models 8000, 8100, 8200 and

9100 doors with a strut (may or may not be supplied). The installation of the drawbar operator must be according to manufacturer’s instructions and force settings must be adjusted properly. Refer to the owner’s manual supplied with your drawbar operator for complete details on installation, operation, maintenance and testing of the operator.

MAINTAINING YOUR GARAGE DOOR:

Before you begin, read all warning labels affixed to the door and the installation 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.

WARNING

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.

GLASS CLEANING INSTRUCTIONS

Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.

ACRYLIC CLEANING INSTRUCTIONS

Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on particles. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic glazing. Dry glazing with a clean damp chamois.

NOTE: Do not use any window cleaning fluids, scouring compounds, gritty cloths or solventbased cleaners of any kind.

Painting Your Garage Door

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.

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

17

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.

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

If you need assistance, please call 1-866-569-3799 (press Option 1) and follow the prompts to contact a customer service representative. 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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Key features

TorqueMaster Plus spring system
Residential use
Detailed installation instructions
Maintenance recommendations
Safety warnings and precautions

Frequently asked questions

Look for the stamped radius on the horizontal track itself.

You will need 12-1/2” of headroom.

The minimum side clearance required is 3-1/2” from the opening to the wall.

The tops of the vertical tracks must be level from side to side. If you shimmed the bottom section to level it, the vertical track on the shimmed side must be raised the height of the shim.

With the horizontal tracks installed, vertically align the top section of the door with the lower sections. Then, position the top fixture slide out against the horizontal track and tighten the 1/4” - 20 flange hex nut to secure the top fixture slide to the top fixture base.