Wayne-Dalton 341458 User Manual
9800 DOORS
TorqueMaster® Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
IMPORTANT NOTICE!
Wayne-Dalton, a Division of
Overhead Door Corporation
P.O. Box 67, Mt. Hope, OH 44660
www.Wayne-Dalton.com
©Copyright 2010 Wayne-Dalton, a Division of Overhead Door Corporation Part No. 341458 REV2 02/26/2010
Read these instructions carefully before attempting
installation. If in question about any of the procedures, do not perform the work. Instead, have a
qualified door agency do the installation or repairs.
Table of Contents
Important Safety Instructions .................................................. 2
Package Contents ................................................................... 3
Door Section Identification ...................................................... 4
Tools Required ........................................................................ 5
WARNING
TO AVOID POSSIBLE
INJURY, READ THESE INSTRUCTIONS
CAREFULLY BEFORE ATTEMPTING
INSTALLATION. IF IN QUESTION ABOUT
Pre-Installation ..................................................................5-10
Removing The Old Door .......................................5-9
Preparing The Opening ......................................... 10
Installation ......................................................................11-32
Optional Installations .......................................................33-34
Side Lock .............................................................33
Pull Rope .............................................................. 33
Trolley Operator .................................................... 34
Maintenance ....................................................................35-36
Cleaning ............................................................... 35
Painting Instructions ............................................. 36
Warranty ............................................................................... 37
Dealer Locator Information.................................................... 38
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.
ANY OF THE PROCEDURES, DO NOT
PERFORM THE WORK. INSTEAD, HAVE
A QUALIFIED DOOR AGENCY DO THE
INSTALLATION OR REPAIRS.
1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.
2. Wear protective gloves during installation to avoid possible cuts
from sharp metal edges.
3. It is always recommended to wear eye protection when using
tools, otherwise eye injury could result.
4. Avoid installing your new door on windy days. Door could fall
during the installation causing severe or fatal injury.
5. Doors 12’ - 0” wide and 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, red colored
fasteners, cables or supports. To avoid possible severe or fatal
injury, have any such work performed by a trained door systems
technician using proper tools and instructions.
12. On electrically operated doors, pull down ropes must be
removed and locks must be removed or made inoperative in the
open (unlocked) position.
13. Top section of door may need to be reinforced when attaching
an electric opener. Check door and/or opener manufacturer’s
instructions.
14. VISUALLY inspect door and hardware monthly for worn and or
broken parts. Check to ensure door operates freely.
15. Test electric opener’s safety features monthly, following opener
manufacturer’s instructions.
16. NEVER hang tools, bicycles, hoses, clothing or anything else
from horizontal tracks. Track systems are not intended or
designed to support extra weight.
After installation is complete, fasten this manual
near garage door.
2
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
9800SERIES
TorqueMaster® Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
IMPORTANT NOTICE!
Read these instructions carefully before
attempting installation. If in question about
any of the procedures, do not perform the
work. Instead, have a qualified door agency
do the installation or repairs.
© Copyright 2007 Wayne-Dalton Corp. Part No. xxxxxx NEW 01/03/2007
MANUAL
Package Contents
NOTE: DEPENDING ON THE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT
NECESSARY. REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR.
DOOR SECTIONS (AS REQUIRED)
(1) TORQUEMASTER® SPRING TUBE
(2) HORIZONTAL TRACKS RH/LH
(2) FULLY ADJUSTABLE RH/LH
FLAGANGLE (AS REQUIRED)
(2) HORIZONTAL ANGLES
(22”, 80” OR 94”)
(AS REQUIRED)
ROLLERS
(1) CENTER BRACKET
(AS REQUIRED)
1/4” - 20 X 7/8” SELF-DRILLING
SCREWS (AS REQUIRED)
(2) QUICK INSTALL RH/LH
FLAGANGLE (AS REQUIRED)
(1) OPERATOR BRACKET
(2) TOP BRACKET BASES
ASSEMBLY
1/4” - 20 X 5/8” SELF-DRILLING
SCREWS (AS REQUIRED)
SCREW EYE AND
PULL ROPE
(IF INCLUDED)
WARNING
.
SIDE VIEW
GED
ENGA
Rachet Bracket is under
remove
EXTREME SPRING
TENSION
DO NOT
To avoid possible severe or
fatal injury,
fasteners from ratchet bracket
wnwound.
until spring(s) are fully
read
Pawl
To safely unwind spring(s)
Ratchet
ATH VIEW
NDERNE
manual.
and follow the directions in the
installation instructions/owners
T REMOVE THIS TAG.
een
RIGHT & LEFT
END BRACKETS
RIGHT AND LEFT CABLE
DRUM ASSEMBLIES
WEATHER SEALS & NAILS
(IF INCLUDED)
(2) TOP BRACKET SLIDES
the Instructions on the other side of
WARNING
DE VIEW
, in conjunction with
.
ENGAGED SI
Rachet Bracket is under
remove
EXTREME SPRING
TENSION
Use these Illustration
Cable Drum
DO NOT
this label.
To avoid possible severe or
fatal injury,
fasteners from ratchet bracket
wnwound.
in the
een Ratchet
until spring(s) are fully
e Drum
ent
read
No space betw
and Cabl
Pawl
Pawl
To safely unwind spring(s)
Ratchet
indicates engagem
manual.
and follow the directions
GED UNDERNEATH VIEW
ENGA
installation instructions/owners
een
DO NOT REMOVE THIS TAG.
and
Pawl
No space betw
SIDE VIEW
Ratchet
Cable Drum
DISENGAGED
Cable Drum
ent
e Drum
Space between Ratchet Pawl
and Cabl
Ratchet Pawl
non-indicates engagem
NDERNEATH VIEW
GED U
TION
DISENGA
n
LOWER POSI
ee
and
Pawl
No space betw
Ratchet
Cable Drum
POSITION
UPPER
er Position
in Low
Ratchet Pawl
ition
SIDE VIEW
Pawl in Upper Pos
POSITION
Ratchet
ER
(1) LOOSE WINDING SHAFT
(SINGLE SPRING ONLY)
RIGHT & LEFT
DRUM WRAPS
DOOR STOP & NAILS
(IF INCLUDED)
Q.I. JAMB BRACKETS
(AS REQUIRED)
1/4” - 14 X 5/8” SELF-TAPPING
SCREWS (AS REQUIRED)
(2) VERTICAL
TRACKS RH/LH
F.A. JAMB BRACKETS
(AS REQUIRED)
(4) 1/4” - 20 X 5/8”
CARRIAGE BOLTS
CLEVIS PIN
1/4” - 20 FLANGED HEX
NUTS (AS REQUIRED)
(1) COTTER PIN(1) 5/16” X 1-1/4”
STUD PLATES
(AS REQUIRED)
(2) 3/8” - 16 X 3/4”
TRUSS HEAD BOLTS
(2) 5/16” - 18 X 3/4”
CARRIAGE BOLTS
(2) 3/8” - 16 HEX
(2) 5/16” - 18
HEX NUTS
NUTS
5/16” X 1 5/8” HEX HEAD LAG SCREWS
1/4” - 20 X 9/16” LARGE
HEAD RIBBED TRACK BOLTS
(AS REQUIRED)
(AS REQUIRED)
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
3
Door Section Identification
TOP SECTION
Tools Needed:
NOTE: This provides an alternative
method for identifying your door
sections/stacking position.
Hinges are always pre-attached at
the top of each section (except top
section) and the hinges are stamped for
identification, #1, #2, and #3. See view
below. The stamp identifies the stacking
sequence of the section. The sequence
is always determined by #1 being the
bottom section to #3 being the highest
lock/intermediate section. See views to
the right. If the stamp on the end hinge
is illegible, refer to the section side view
illustration to the right.
The section side view illustration shows
the end hinge profile of all the sections,
and can also be used in conjunction
with identifying each sections.
The BOTTOM SECTION can be
identified by #1 end hinges, the factory
attached bottom astragal, and by the
bottom bracket warning labels on each
end stile.
ASTRAGAL
#3
WARNING LABEL
#1
BOTTOM BRACKET
WARNING LABELS
3 SECTION 7’0” HIGH SHOWN ABOVE
#3
INTERMEDIATE SECTION
#2
BOTTOM SECTION
TOP SECTION
WARNING LABEL
LOCK SECTION
The LOCK SECTION can be identified
by #2 end hinge.
NOTE: On 3 section high doors, the
LOCK SECTION can be identified by
#3 end hinge and the section will have
a warning label attached to either the
right or left hand end stile.
The INTERMEDIATE SECTION can be
identified by #3 end hinges. The section
will have a warning label attached to
either the right or left hand end stile.
The TOP SECTION can be identified by
no pre-installed hinges on the section
and the warning label attached in the
center of the section.
LOCK SECTION
#1
BOTTOM BRACKET
WARNING LABELS
ASTRAGAL
4 SECTION 8’0” HIGH SHOWN ABOVE
TOP INT. LOCK BOTTOM
BOTTOM SECTION
1 3/8”
#3 END
HINGE
#2 END
HINGE
1 1/8”
7/8”
#1 END
HINGE
BOTTOM
BRACKET
ASTRAGAL
TYPICAL HINGE STAMPING LOCATION
4
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yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
SECTION SIDE VIEW SHOWN ABOVE
Tools Required
POWER DRILL RATCHET WRENCH PLIERS/WIRE CUTTERS
PHILLIPS HEAD SCREWDRIVER PENCIL
7/16”, 1/2”, 9/16”
SOCKETS
HAMMER
FLAT TIP SCREWDRIVER
7/16” SOCKET DRIVER
VICE GRIPS VICE CLAMPS
3/8”, 7/16”, 1/2”, 9/16”
WRENCHES
Removing An Old Door
TAPE MEASURE
NEEDLE NOSE PLIERS
SAFETY GLASSES
(2) SAW HORSES
1/8”, 3/16” DRILL BITS
PRE-INSTALLATION
GLOVES
STEP LADDER
WARNING
IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED IN SECTIONS P1, P2 AND P3, DO NOT
ATTEMPT TO WORK ON IT, BUT HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK. OTHERWISE, SEVERE OR
FATAL INJURY COULD RESULT.
WARNING
DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO
PREVENT UNINTENDED DOOR OPERATION. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
WARNING
COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL
SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.
WARNING
IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS, OR SEVERE INJURY COULD RESULT
WARNING
REMOVING AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSTRUCTIONS ON PAGES 6-10 “REMOVING AN OLD
DOOR/PREPARING THE OPENING” CAREFULLY, OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
If you have an existing door, follow the instructions to identify which counterbalance removal is necessary. The process of removing
an existing door begins by identifying it’s counterbalance system. If you are not removing an existing door, proceed to PREPARING THE
OPENING on page 10. Generally, you will find three (3) types of counterbalance systems: Torsion spring counterbalance systems, WayneDalton® exclusive TorqueMaster® and Extension Spring counterbalance systems.
For more technical information regarding the opening preparation, installation and use of your garage door and opener, you can go to
www.dasma.com and click on Publications and then Technical Data Sheets Number 156, 161 and 164.
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
5
P1
Torsion Spring Removal
For Standard Lift
SET SCREWS
Tools Needed:
Approved
Winding Bars
3/8” Wrench
Vice Clamp
Recommended
tools from
page 5
WARNING
FAILURE TO USE APPROVED
WINDING BARS CAN CAUSE
SPRING ENERGY TO BE RELEASED
SUDDENLY, RESULTING IN SEVERE
OR FATAL INJURY.
WARNING
COUNTERBALANCE SPRING
TENSION MUST BE RELIEVED
BEFORE REMOVING ANY
HARDWARE. A POWERFUL
SPRING RELEASING IT’S ENERGY
SUDDENLY CAN CAUSE SEVERE OR
FATAL INJURY.
Do not release the torsion spring
tension unless you are qualified and
experienced door technician. Instead have
a professional door agency release the
tension.
Step 1: Close the door and place vice
clamps on the back legs of both vertical
tracks, above the third roller to prevent
the door from lifting as you unwind the
springs. Use only approved winding bars
available from your dealer. Do not use
undersized steel rods, screw drivers or
anything else to unwind the springs.
Position the ladder just off to the side
of the winding cone. The winding cone
should be easy to reach without putting
your body directly in front of it.
FIRMLY HOLD WINDING
BAR AND CAUTIOUSLY
LOOSEN SET SCREWS
WINDING CONE
WINDING CONE
Step 2: Insert a winding bar into one
of the holes in the winding cone. Exert
upward pressure. Using caution, loosen
the two (2) set screws in the winding
cone. Be prepared to support the full
torsional force of the spring when the set
screws are loosened.
Step 3: Once set screws are loose, slowly
and carefully lower the winding rod until it
contacts the door. Insert other winding bar
into the upper hole. Push up and remove
lower bar. Carefully lower upper winding
bar, 1/4 turns at a time until it contacts
the door. Repeat process until all tension
is relieved. If your door is equipped with
two (2) torsion springs, follow the same
procedure to relieve tension on the second
spring.
Step 4: Remove vice clamps from tracks,
unbolt torsion shaft assembly and remove
from work area.
NOTE: Continue with “P4” on page 9 after
completing this step.
6
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APPROVED WINDING BARS
TORSION ASSEMBLY
P2
TorqueMaster® Spring Removal
LOOSEN LOCK
NUT 1/4 TURN
COUNTER
GEAR / COVER
Tools Needed:
Recommended
tools from
page 5
A TorqueMaster® spring system can be
identified by the end brackets. For single
spring applications, the right hand end
bracket will always have a drive gear,
counter gear, counter cover, and a winding
bolt head. The left hand end bracket will
have no gears, counter cover, or winding
bolt head. The hole for the winding bolt
head will be plugged.
For double springs, both the right hand
and left hand end brackets will always
have a drive gear, counter gear, counter
cover and a winding bolt head.
IMPORTANT: RIGHT AND LEFT HAND IS
ALWAYS DETERMINED FROM INSIDE THE
BUILDING LOOKING OUT.
Step 1: If you have a black counter
cover: Place a mark on the drive gear
tooth and an adjacent mark on the right
hand end bracket (Fig. 1). Loosen the lock
nut 1/4 turn using a 7/16” wrench and
continue with step 2.
If you have a gray counter cover:
Loosen the lock nut 1/4 turn using a 7/16”
wrench and continue with step 2.
Step 2: Using an electric drill (High
torque / gear reduced to 1300 rpm
preferred) with a 7/16” hex head driver,
unwind the right hand winding bolt head
counterclockwise (Fig. 2) and count the
number of turns the mark on the drive
gear passes the adjacent mark on the end
bracket. Referencing the chart below, by
door height, stop unwinding the spring
once the counted turns have reached the
listed number of turns.
6’-0” Door Height = 14 turns
6’-3” Door Height = 14 1/2 turns
6’-5” Door Height = 15 turns
6’-6” Door Height = 15 turns
6’-8” Door Height = 15 1/2 turns
6’-9” Door Height = 15 1/2 turns
7’-0” Door Height = 16 turns
7’-3” Door Height = 16 1/2 turns
7’-6” Door Height = 17 turns
7’-9” Door Height = 17 1/2 turns
8’-0” Door Height = 18 turns
CAUTION:
DO NOT USE IMPACT GUN TO
UNWIND SPRINGS.
IMPORTANT: DO NOT REFERENCE THE
COUNTER COVER WHEN COUNTING THE
NUMBER OF TURNS BEING UNWOUND
ON THE SPRING, BUT FOLLOW THE
INSTRUCTIONS ABOVE.
RIGHT HAND
CABLE DRUM
TORQUEMASTER®
SPRING TUBE
Fig. 1
END BRACKET
Fig. 2
Fig. 3
RIGHT HAND
END BRACKET
PLACE MARK ON END BRACKET
AND DRIVE GEAR TOOTH
BEFORE UNWINDING SPRINGS
RIGHT HAND
WINDING BOLT HEAD
ELECTRIC DRILL
WITH 7/16” HEX
DRIVER (DO NOT
USE IMPACT
GUN)
CHECK CABLE
TENSION
COUNTER
GEAR
COUNTER
COVER
PRE-INSTALLATION
Step 3: Verify that spring tension has been
released by pulling the counterbalance
cable on the right hand cable drum away
from the header (Fig. 3). If spring tension
has been released, the cable will be loose.
PRY COUNTER GEAR
AND COUNTER COVER
FROM END BRACKET
USING FLAT TIP
SCREWDRIVER
In addition, the TorqueMaster® Spring
Tube
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yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Fig. 4
7
TorqueMaster® Spring
Removal Continued...
Tools Needed:
Recommended
tools from
page 5
should be free to rotate in either direction.
If the counterbalance cable is still taut and
the TorqueMaster® Spring Tube is difficult
to rotate, that is an indication that spring
tension still exists on the left hand spring.
Repeat Steps 1 and 2 for releasing spring
tension on the left hand side.
Step 4: Using a flat tip screwdriver,
pry the counter gear and counter cover
from the right hand end bracket (Fig. 4
on previous page). Discard the counter
gear and counter cover. On double spring
applications, repeat for left hand side.
Step 5: Remove the upper 5/16” x
1-5/8” lag screw from the right hand end
bracket (Fig. 5). Attach locking pliers to
the upper portion of the end bracket and
hold the housing steady while removing
the lower 5/16” x 1-5/8” lag screw and
#10 x 1/2” phillips head screw from the
end bracket (Fig. 6).
Step 6: Holding the right hand end
bracket steady with locking pliers,
carefully pry the end bracket and drive
gear off the winding shaft using a flat tip
screwdriver (Fig. 7).
CAUTION: THE WINDING SHAFT MAY
ROTATE WHEN REMOVING THE END
BRACKET AND DRIVE GEAR.
Step 7: Repeat Step 4 for the left hand
side. Holding the left hand end bracket
steady with locking pliers, carefully pry
the end bracket off the winding shaft
using a flat tip screwdriver (Fig. 7).
Step 8: Remove the two (2) lag bolts
attaching the center bracket assembly to
the header board (Fig. 8).
REMOVE TOP
LAG SCREW
Fig. 5
USE LOCKING PLIERS
TO HOLD END BRACKET
REMOVE #10
PHILLIPS HEAD
SCREW
REMOVE
BOTTOM LAG
SCREW
Fig. 6
HOLD THE
END BRACKET
STEADY WITH
LOCKING PLIERS
PRY END BRACKET FROM WINDING
SHAFT USING A FLAT TIP SCREW
DRIVER AND LOCKING PLIERS
Step 9: Lift the right hand side of the
TorqueMaster® Spring Tube and slide the
cable drum off. Realign the groove in the
winding shaft with the radial notch in the
flagangle and drape the counterbalance
cable with drum over the flagangle. Lift
the left hand side of the TorqueMaster®
CENTER
BRACKET
ASSEMBLY
Fig. 7
REMOVE CABLE DRUM AND
WINDING SHAFT
Spring Tube and slide the cable drum
and winding shaft off (Fig. 9). Drape the
counterbalance cable with drum over the
flagangle. Lift the TorqueMaster® spring
assembly off the flagangles and out of
the doorway. Unhook the counterbalance
cables from the bottom brackets and
remove all parts from the work area.
NOTE: The cable drums may be difficult to
remove. If so, twist the cable drum to aid
in removal.
NOTE: Continue with “P4” on page 9 after
completing this step.
8
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yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
(2) 5/16” X 1-5/8”
HEX HEAD LAG
SCREWS
DRAPE CABLE
ACROSS
TOP OF FLAGANGLE
TORQUEMASTER®
SPRING TUBE
OFF FLAGANGLE
LIFT
P3
Tools Needed:
Recommended
tools from
page 5
Extension Spring Removal
Step 1: Raise the door to the fully open
position and place vice clamps to the
back legs of both vertical tracks, below
the bottom rollers to prevent the door
from falling. By opening the door you
release most of the spring tension.
Carefully unfasten the S-hook from the
horizontal angle. Remove cable, sheave
and extension spring. Repeat for the other
side. If safety cables are running through
the extension springs, remove them also.
Remove parts from work area.
Step 2: Holding door in the open position,
remove the vice clamps, be prepared
to support the entire weight of the door.
Garage doors can weigh 200-400 pounds.
With assistance, carefully lower the door,
by grasping the door firmly by it’s lift
handles. Do not place fingers or hands
near joints, between sections, or between
bottom of door and floor. Otherwise,
severe injury could result.
REMOVE LAG SCREW
FROM SAFETY CABLE (IF
INSTALLED). REPEAT FOR
OPPOSITE SIDE.
BOTTOM SECTION
(DOOR OPEN)
PRE-INSTALLATION
CAREFULLY REMOVE “S”
HOOK AND COUNTERBALANCE
CABLE (REPEAT FOR THE
OPPOSITE SIDE)
HORIZONTAL ANGLE
P4
Tools Needed:
Recommended
tools from
page 5
NOTE: Continue with “P4” after completing
this step.
Removing the Old Door
Having removed the counterbalance
system, the door can now be
disassembled.
Start by first removing the top row of
hinges.
With assistance, hold the top section to
keep it from falling and remove the
top brackets. With assistance, lift the top
section out of the opening and remove
it from the work area. Repeat for all
remaining sections.
After door is disassembled, unbolt both
track assemblies from the jambs and
remove all material from the work area.
You can neatly dispose of the old door by
placing it in the carton of your new door.
TOP BRACKET
HORIZONTAL TRACK
HINGES
Clean up area and complete “Preparing
the Opening” “P5” on page 10 before
installing the new door.
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9
SUITABLE MOUNTING SURFACE
2” X 6” LUMBER MINIMUM
LEVEL HEADER
PLUMB JAMBS
DOOR
HEIGHT
P5
Tools Needed:
Recommended
tools from
page 5
Preparing the Opening
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.
HEADER BOARD
2” X 6” LUMBER
PREFERRED
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
DOOR
WIDTH
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,
HEADER
HEADROOM
BACKROOM
MUST BE REPLACED.
For TorqueMaster counterbalance systems, a suitable
mounting surface (2” x 4”) must be firmly attached to the
JAMB
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.
Weather Seal (May Not Be Included):
JAMB
WEATHER SEAL
Cut the weather seal (if necessary) to fit header and jambs.
For quick install track: Align the header seal with the inside
edge of the header and temporarily secure it to the header
with equally spaced nails. Next, fit the jamb seals up tight
against the header seal and flush with the inside edge of
the jamb. Temporarily secure the jamb seals with equally
spaced nails approximately 12” to 18” apart. This will keep
WEATHER SEAL
the bottom section from falling out of the opening during
installation.
For fully adjustable track: Align the header seal 1/8” to
WEATHER
SEAL
1/4” inside the header and temporarily secure it to the
header with equally spaced nails. Next, fit the jamb seals
up tight against the header seal and 1/8” to 1/4” inside
1/8” TO 1/4”
the jamb. Temporarily secure the jamb seals with equally
spaced nails approximately 12” to 18” apart. This will keep
the bottom section from falling out of the opening during
installation.
NOTE: Do not permanently attach weather seal to the jamb
at this time.
HEADROOM REQUIREMENT: Headroom is defined as the
space needed above the top of the door for tracks, springs,
etc. to allow the door to open properly. If the door is to be
motor operated, 2-1/2” (64 mm) of additional headroom is
required.
NOTE: 6” LHR Conversion Kit is available for 12” Radius only.
Contact your local Wayne-Dalton dealer.
BACKROOM REQUIREMENT: Backroom is defined as the
JAMB
QUICK INSTALL TRACK FULLY ADJUSTABLE TRACK
DOOR
STOP
DOOR
SECTION
JAMB
HEADROOM REQUIREMENT
TRACK TYPE TorqueMaster
15” Radius track 12-1/2” (318 mm)
BACKROOM REQUIREMENT
DOOR HEIGHT TRACK MANUAL LIFT
distance needed from the opening back into the garage to
allow the door to open fully.
10
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
6’6”, 7’0” 15” Radius 98” (2489 mm) 125” (3175 mm)
8’0” 15” Radius 110” (2794 mm) 137” (3480 mm)
JAMB
JAMB
DOOR
STOP
1/8” TO 1/4”
®
MOTOR
OPERATED
WEATHER
SEAL
DOOR
SECTION
Installation
IMPORTANT: READ INSTRUCTIONS TITLED “P4” “REMOVING THE OLD DOOR” ON PAGE 9 AND “P5” “PREPARING THE OPENING” ON
PAGE 10 BEFORE ATTEMPTING DOOR INSTALLATION.
IMPORTANT: STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS,
END BRACKETS, JAMB BRACKETS, OPERATOR MOUNTING/SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER
(PRESERVATIVE-TREATED). STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED
LUMBER.
NOTE: It is recommended that 5/16” x 1-5/8” lag screws be pilot drilled using a 3/16” drill bit, and 1/4” x 2” lag screws and
1/4” x 1-1/2” lag screws be pilot drilled using a 1/8” drill bit, prior to fastening.
INSTALLATION
1
Tools Needed:
None
Attaching Quick Install Flag
Angle to Vertical Track
NOTE: If you have fully adjustable
flagangle, skip this step and complete
Step 2.
Place the lower quick install tab of the
flagangle in the quick install feature of
the vertical track. Give the flagangle 1/4
turn to lock in place. Repeat for other
side.
NOTE: After completing this step,
continue with Step 3.
QUICK INSTALL TAB UNLOCKED QUICK INSTALL TAB LOCKED
FLAGANGLE
FLAGANGLE
VERTICAL
TRACK
VERTICAL
TRACK
LEFT HAND TRACK AND FLAGANGLE
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
RIGHT HAND TRACK AND FLAGANGLE
11
2
Attaching Fully Adjustable
Flagangle to Vertical Track
FULLY ADJUSTABLE FLAGANGLE
Tools Needed:
None
NOTE: If quick install flagangle was
installed in Step 1, skip this step and
continue with Step 3. If not, complete
this step.
Hand tighten the flagangle to the vertical
track using (2) 1/4” - 20 x 9/16” large
head ribbed track bolts (or stud plate if
included) and (2) 1/4” - 20 flange hex
nuts. Repeat for other side.
Secure the flange nuts after flagangle
spacing is complete (Step 12).
1/4”- 20
FLANGE HEX
NUTS
VERTICAL TRACK
STUD PLATE
(IF INCLUDED)
1/4” - 20 X 9/16”
LARGE HEAD RIBBED
TRACK BOLTS
3
Tools Needed:
Hammer
Horizontal Angle
Position the horizontal angle as shown.
Place tabs of horizontal angle in the
key slots of horizontal track. Using
a hammer, tap the horizontal angle
towards the curved end of the track until
the holes in track and angle are aligned.
Set tracks aside.
NOTE: For larger doors, a full length
horizontal angle may be spot welded to
the horizontal track. If the horizontal angle
is not welded, the horizontal angle will be
installed as shown.
HOLE
HORIZONTAL ANGLE
HOLE
TABS
HORIZONTAL
ANGLE
HORIZONTAL
TRACK
HORIZONTAL
TRACK
HAMMER
KEY SLOT
HORIZONTAL
TRACK
HORIZONTAL
ANGLE
HORIZONTAL
TRACK
HOLES
ALIGNED
12
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
TABS
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