Wayne-Dalton 341785 User Manual

Page 1

9800 Series - 4 Section

Low Head Room Front Mount Torsion Spring

Installation Instructions and Owner’s Manual

Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.wayne-dalton.com

Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work. Instead, have a qualiﬁed door agency do the installation or repairs.

IMPORTANT NOTICE!

Page 2

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

Pre-Installation ..................................................................5-10

Removing The Old Door .......................................5-9

Preparing The Opening ......................................... 10

Installation ......................................................................11-28

Optional Installations .......................................................29-30

Side Lock .............................................................29

Pull Rope .............................................................. 29

Trolly Operator ...................................................... 30

Maintenance ....................................................................31-32

Cleaning ............................................................... 31

Painting Instructions ............................................. 32

Warranty ............................................................................... 33

Dealer Locator Information.................................................... 34

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.

ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A QUALIFIED DOOR AGENCY DO THE INSTALLATION OR REPAIRS.

1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2. Wear protective gloves during installation to avoid possible cuts from sharp metal edges.

3. It is always recommended to wear eye protection when using tools, otherwise eye injury could result.

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

5. Doors 12’ - 0” wide and 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.

To find your Wayne-Dalton dealer; refer to your local yellow pages / business listings or go to Find a dealer area online at www.wayne-dalton.com

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

Page 3

Package Contents

Low Head Room Front Mount Torsion Spring

Installation Instructions and Owner’s Manual

9800 Series - 3 Section

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 qualiﬁ ed door agency do the installation or repairs.

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) TORSION TUBE

(2) FULLY ADJUSTABLE RH/LH

FLAGANGLE (AS REQUIRED)

RIGHT & LEFT DRUMS

(2) QUICK INSTALL RH/LH

FLAGANGLE (AS REQUIRED)

TORSION SPRINGS

(AS REQUIRED)

RIGHT AND LEFT

COUTNERBALANCE CABLE

MANUAL RIGHT & LEFT

Q.I. JAMB BRACKETS

(AS REQUIRED)

(1) CENTER BRACKET

END BEARING BRACKET

(2) BOTTOM BRACKETS

FULLY ADJUSTABLE JAMB BRACKETS (AS REQUIRED)

(2) HORIZONTAL TRACK RH/LH

(1) OPERATOR BRACKET

DOOR STOP & NAILS

(IF INCLUDED)

ROLLERS

(AS REQUIRED)

(2) TOP BRACKET

WEATHER SEAL & NAILS

(IF INCLUDED)

(1) CENTER BRACKET

BUSHING

(2) VERTICAL

TRACK RH/LH

PULL ROPE

(IF INCLUDED)

(2) 3/8” FLAT

WASHERS

(2) CLEVIS PINS

(2) COTTER PINS

(2) 5/16” FLAT

WASHERS

3/8”- 16 HEX NUTS

(AS REQUIRED)

1/4”-14 X 5/8” SELF TAPPING

SCREWS (AS REQUIRED)

3/8” -16 X 1-1/2” HEX HEAD

BOLTS (AS REQUIRED)

1/4”- 20 FLANGED HEX

NUTS (AS REQUIRED)

(2) 1/4”-20 X 5/8” TAMPER

RESISTANT SCREWS (AS REQUIRED)

5/16” X 1 5/8” HEX HEAD LAG

SCREWS (AS REQUIRED)

1/4” - 20 X 9/16” TRACK

BOLTS (AS REQUIRED)

1/4”-20 X 5/8” SELF DRILLING

SCREWS (AS REQUIRED)

5/16” X 2” TAMPER PROOF LAG

(4) 1/4”-20 X 9/16” LARGE

HEAD RIBBED TRACK BOLTS

1/4”-20 X 7/8” SELF DRILLING

SCREWS (AS REQUIRED)

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Page 4

Door Section Identification

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, #3, and #4 (#4 only on ﬁve section doors). 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 or #4 being the highest 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.

The LOCK SECTION can be identiﬁed by a #2 end hinge.

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. NOTE: #4 End hinges are used on the fourth section of ﬁve section doors.

ASTRAGAL

TOP SECTION

WARNING LABEL

(MAYBE ON RIGHT

OR LEFT HAND SIDE)

INTERMEDIATE SECTION

LOCK SECTION

BOTTOM BRACKET

WARNING LABELS

BOTTOM SECTION

SECTION SIDE VIEW

1 3/8”

1 1/8”

7/8”

The TOP SECTION can be identiﬁed by the pre-attached u-bar and no pre-installed end or center hinges on the section.

TYPICAL HINGE STAMPING LOCATION

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U-BAR

TOP

#3 END HINGE

INT.

#2 END HINGE

ASTRAGAL

#1 END HINGE

BOT.LOCK

BOTTOM BRACKET

Page 5

Tools Required

POWER DRILL RATCHET WRENCH

PHILLIPS HEAD SCREWDRIVER

7/16”, 1/2”, 9/16”

SOCKETS

HAMMER

Removing An Old Door

PENCIL

FLAT TIP SCREWDRIVER

7/16” SOCKET DRIVER

VICE GRIPS VICE CLAMPS

1/4” TORX BIT

7/16”, 1/2”, 3/8”, 9/16”

WRENCHES

LEVEL

TAPE MEASURE

APPROVED WINDING

BARS

SAFETY GLASSES

SAW HORSES (PAIR)

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.

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Page 6

Torsion Spring Removal

For Standard Lift

Tools Needed:

Approved

Winding Bars

3/8” Wrench

(2) Vice Clamps

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 a qualiﬁed and experienced door technician. Instead have a professional door agency release the tension.

Step 1: Close the door and place vice clamps on the back legs of both vertical tracks, above the third roller to prevent the door from lifting as you unwind the springs. Use only approved winding bars available from your dealer. Do not use undersized steel rods, screw drivers or anything else to unwind the springs. Position the ladder just off to the side of the winding cone. The winding cone should be easy to reach without putting your body directly in front of it.

Step 2: Insert a winding bar into one of the holes in the winding cone. Exert upward pressure. Using caution, loosen the two (2) set screws in the winding cone. Be prepared to support the full torsional force of the spring when the set screws are loosened.

Step 3: Once set screws are loose, slowly and carefully lower the winding rod until it rests against the door. Insert other winding bar into the upper hole. Push up and remove lower bar. Carefully lower upper winding bar, 1/4 turns at a time until it rests against 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.

TORSION SPRING ASSEMBLY

WINDING CONE

APPROVED WINDING BAR

SET SCREWS

FIRMLY HOLD WINDING BARS AND

CAUTIOUSLY LOOSEN SET SCREWS

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Page 7

Tools Needed:

Recommended

tools from

page 5

TorqueMaster® Spring Removal

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

LOOSEN LOCK

NUT

COUNTER

GEAR/ COVER

RIGHT HAND

END BRACKET

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:

Fig. 1

PLACE MARK ON END BRACKET

AND DRIVE GEAR TOOTH

BEFORE UNWINDING SPRINGS

END BRACKET

RIGHT HAND

WINDING BOLT HEAD

Place a mark on the drive gear tooth and an adjacent mark on the right hand end bracket (Fig. 1). Loosen the lock nut using a 7/16” wrench and continue with step 2. If you have a gray counter cover: Loosen the lock nut using a 7/16” wrench and continue with step 2.

ELECTRIC DRILL WITH 7/16” HEX

DRIVER (DO NOT

USE IMPACT

GUN)

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

RIGHT HAND

CABLE DRUM

Fig. 2

door height, stop unwinding the spring once the counted turns have reached the listed number of turns.

6’-0” Door Height = 14 turns

TORQUEMASTER®

SPRING TUBE

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

CHECK CABLE

TENSION

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

Fig. 3

COUNTER

GEAR

COUNTER COVER WHEN COUNTING THE NUMBER OF TURNS BEING UNWOUND ON TH E SP R I N G, BU T F O L L O W THE INSTRUCTIONS ABOVE.

Step 3: Verify that spring tension has been released by pulling the counterbalance cable on the right hand cable drum away from the header (Fig. 3). If spring tension has been released, the cable will be loose. In addition, the TorqueMaster® Spring

PRY COUNTER GEAR

AND COUNTER COVER

FROM END BRACKET

USING FLAT TIP

SCREWDRIVER

COUNTER

COVER

Tube should be free to rotate in either direction.

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Fig. 4

PRE-INSTALLATION

Page 8

TorqueMaster® Spring

Removal continued...

Tools Needed:

(Spring Tube should be free to rotate in either direction.) If the counterbalance

Recommended

tools from

page 5

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

REMOVE TOP

LAG SCREW

Fig. 5

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.

USE LOCKING PLIERS

TO HOLD END BRACKET

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

REMOVE #10

PHILLIPS HEAD

SCREW

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

REMOVE

BOTTOM LAG

SCREW

Fig. 6

HOLD THE

END BRACKET

STEADY WITH

LOCKING PLIERS

side. Holding the left hand end bracket steady with locking pliers, carefully pry the end bracket off the winding shaft using a ﬂat tip screwdriver (Fig. 7).

Step 8: Remove the two (2) lag bolts attaching the center bracket assembly to the header board (Fig. 8).

Step 9: Lift the right hand side of the TorqueMaster

Spring Tube and slide the

PRY END BRACKET FROM WINDING

SHAFT USING A FLAT TIP SCREW

DRIVER AND LOCKING PLIERS

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® Spring Tube and slide the cable drum

CENTER

BRACKET

ASSEMBLY

Fig. 7

REMOVE CABLE DRUM AND

WINDING SHAFT

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.

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(2) 5/16” X 1-5/8”

HEX HEAD LAG

SCREWS

Fig. 8

DRAPE CABLE

ACROSS

TOP OF

FLAGANGLE

Fig. 9

LIFT

TORQUEMASTER®

SPRING TUBE

OFF FLAGANGLE

Page 9

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 COUNTREBALANCE

CABLE (REPEAT FOR THE

OPPOSITE SIDE)

HORIZONTAL ANGLE

Tools Needed:

Recommended

tools from

page 5

NOTE: Continue with “P4” on page 9 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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Page 10

SUITABLE MOUNTING

SURFACE 2” X 6”

LUMBER MINIMUM

DOOR HEIGHT

Tools Needed:

Recommended

tools from

page 5

Preparing the Opening

WARNING

MOUNTING PAD TO STRUCTURALLY SOUND FRAMING COULD CAUSE SPRINGS TO VIOLENTLY PULL MOUNTING PAD FROM WALL, RESULTING IN SEVERE OR FATAL INJURY. If you just removed your existing door or you are installing a new door, complete all steps in PREPARING THE OPENING.

FAILURE TO SECURELY ATTACH A SUITABLE

HEADER BOARD 2” X 6” LUMBER

PREFERRED

LEVEL HEADER

PLUMB JAMBS

To ensure secure mounting of track brackets, side and center bearing 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.

DOOR

WIDTH

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 14” (356 mm) above the top of the opening for Torsion spring applications. For low headroom applications, the jambs should extend to the ceiling height. Minimum side

HEADER

HEADROOM

BACKROOM

clearance required, from the opening to the wall, is 3-1/2” (89 mm). IMPORTANT: CLOSELY INSPECT EXISTING JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD FOUND

JAMB

NOT TO BE SOUND, MUST BE REPLACED. For Torsion spring applications, a suitable mounting surface must be ﬁrmly attached to the wall, above the header at the center of the opening. The mounting surface must be 2” x 6” lumber minimum (Select southern yellow pine lumber. Do not use lumber marked as spruce-pine-

WEATHER SEAL

fur or SPF). The mounting surface must be securely attached to the wall with four (4) 3/8” anchors for masonry constructions or four (4) 5/16” x 4” lag screws for wood construction.

JAMB

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)

Cut the weather seal or door stop (if necessary) to ﬁt header and jambs.

/ Door stop:

WEATHER

SEAL

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 the bottom section from falling out of the opening during installation. For fully adjustable track: Align the header seal 1/8” to 1/4” inside the header and temporarily secure it to the header with equally spaced nails. Next, ﬁt the jamb seals up tight against the header seal and 1/8” to 1/4” inside the jamb. Temporarily secure the jamb seals with equally 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 or door stop to the jamb at this time.

JAMB

QUICK INSTALL TRACK

DOOR

STOP

DOOR

SECTION

JAMB

HEADROOM REQUIREMENT

TRACK TYPE TorqueMaster

6” LHR 6” (152.4 mm)

1/8” TO 1/4”

JAMB

FULLY ADJUSTABLE TRACK

JAMB

1/8” TO 1/4”

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.

DOOR HEIGHT TRACK

BACKROOM REQUIREMENT: Backroom is deﬁned as the

distance needed from the opening back into the garage to allow the door to open fully.

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BACKROOM REQUIREMENT

8’0” 15” Radius

MANUAL

LIFT

110”

(2794 mm)

OPERATED

(3480 mm)

WEATHER

SEAL

DOOR

STOP

DOOR

SECTION

MOTOR

137”

Page 11

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 PT 2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, OPERATOR MOUNTING/SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON 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

Tools Needed:

None

Attaching Quick Install

Flagangle 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

FLAGANGLE

VERTICAL

TRACK

QUICK INSTALL TAB LOCKED

FLAGANGLE

VERTICAL

TRACK

LEFT HAND TRACK AND FLAGANGLE

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RIGHT HAND TRACK AND FLAGANGLE

Page 12

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 10).

1/4”- 20

FLANGE HEX

NUTS

VERTICAL TRACK

STUD PLATE

(IF INCLUDED)

1/4” - 20 X 9/16”

LARGE HEAD RIBBED

TRACK BOLTS

Installing Quick Install

Tools Needed:

None

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NOTE: If you have fully adjustable jamb

brackets, skip this step and complete Step 4.

Measure the length of the vertical tracks. Using the jamb bracket schedule, determine the placement of the jamb brackets for your door height and track type. To install the jamb brackets, align the twistlock tab on the quick install jamb bracket with the quick install feature in the track and turn the bracket perpendicular to the track so the mounting ﬂange is toward the back (ﬂat) leg of the track.

NOTE: After completing this step, continue with Step 5.

Jamb Brackets

LEFT SIDE SHOWN RIGHT SIDE SHOWN

TWISTLOCK TAB

TOP HOLE

MIDDLE HOLE

QI JAMB BRACKET

BOTTOM

JAMB BRACKET SCHEDULE

DOOR

HEIGHT

8’0”

96” TRACK

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1ST SET 2ND SET 3RD SET

JAMB BKT POSITION JAMB BKT POSITION JAMB BKT POSITION

QIJB - 3 BOTTOM QIJB - 7 TOP QIJB - 8 TOP

HOLE

QUICK INSTALL FEATURE

3RD SET HOLES

2ND SET HOLES

1ST SET HOLES

Page 13

Installing Fully Adjustable

Jamb Brackets

FULLY ADJUSTABLE JAMB BRACKETS

Tools Needed:

None

NOTE: If quick install ﬂagangles were installed in Step 3, skip this step and continue with Step 5. If not, complete this step.

The bottom jamb bracket is always the shortest bracket included with your door. If three jamb brackets are included with the door, the middle bracket on the track is the middle bracket in height. The top jamb bracket is the tallest bracket included.

To attach the bottom jamb bracket, locate the lower hole/slot pattern of the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/slot pattern in the vertical track. Loosely hand fasten the bracket onto the track with (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”- 20 ﬂange hex nut.

Place the center jamb bracket over the hole/slot pattern that is centered between the bottom jamb bracket and ﬂagangle. Align the slot in the jamb bracket with the lower hole of the hole/slot pattern. Loosely hand fasten the bracket onto the track with (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”- 20 ﬂange hex nut.

(1) 1/4”-20

FLANGE

HEX NUT

JAMB BRACKET

JAMB

BRACKET

ST-0 ST-1

HOLE/SLOT

PATTERN

(1) 1/4”-20 X 9/16”

TRACK BOLT

VERTICAL

TRACK

INSTALLATION

VERTICAL

TRACK

Repeat if a third jamb bracket is provided, equally spacing the distance between the two center jamb brackets and the bottom jamb bracket and ﬂagangle.

NOTE: While the bottom jamb bracket is the shortest in length that is included with your door. It does not necessarily mean it is the “short” (ST-0) jamb bracket.

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3RD SET

2ND SET

1ST SET

Page 14

Tools Needed:

Power Drill

7/16” Socket

Driver

Bottom Bracket

IMPORTANT: Right and left hand is

always determined from inside the garage looking out.

NOTE: For door section identiﬁcation see page 4.

(4) 1/4”-20 X 11/16” SELF

DRILLING SCREWS

BOTTOM SECTION

CLEVIS

TEARDROP OF

COUNTERBALANCE

CABLE

Locate the left hand bottom bracket. Align the bracket horizontally with the top edge of the pre-installed bottom bracket. Also align the bracket vertically with the left edge of the bottom section. Attach the bracket using (4) 1/4”- 20 x 11/16” self drilling screws and (1) 1/4” - 20 x 5/8” tamper proof screw as shown.

Uncoil the counterbalance cables. Place clevis pin into the inside tab of the bracket and slide the teardrop of the counterbalance cable onto pin. Continue sliding clevis pin thru the outside tab of the bracket. Place a washer onto mildford pin and secure in place using a cotter pin as shown.

Insert a roller into the pre-attached bottom bracket of the bottom section and insert another roller at #1 end hinge at the top of the bottom section.

Repeat for other side.

NOTE: Verify astragal (bottom seal) is aligned with door section. If there is more than 1/2” excess astragal on either side, trim astragal even with door section.

(1) 1/4”- 20 X 5/8”

TAMPER PROOF SCREW

BOTTOM BRACKET ASSEMBLY

BOTTOM

BRACKET

3/8” FLAT

WASHER

COUNTERBALANCE

CABLE

BOTTOM

BRACKET

COTTER

BOTTOM

BRACKET

COUNTERBALANCE

ASSEMBLY

BOTTOM SECTION

ROLLER

PRE-ATTACHED

BOTTOM BRACKET

BOTTOM SECTION

ASTRAGEL

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Page 15

Tools Needed:

Level

Bottom Section

DOOR OPENING

Before installing the bottom section, the weather seal (may not be included) must be installed (see PREPARING THE OPENING on page 10)

Center the bottom section in the door opening. Level section using wooden shims (if necessary) under the bottom astragal.

WEATHER SEAL

LEVEL

BOTTOM SECTION

INSTALLATION

Tools Needed:

3/16” Drill Bit

Power Drill

7/16” Socket

Driver

Tape Measure

Level

Vertical Track

IMPORTANT: THE TOPS OF THE

VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT. THE VERTICAL TRACK ON THE SHIMMED SIDE, MUST BE RAISED THE HEIGHT OF THE SHIM.

Position the left hand vertical track assembly over the rollers of the bottom section. Make sure the counterbalance cable is located between the rollers and the door jamb. Drill 3/16” pilot holes for the lag screws. Loosely fasten jamb brackets and ﬂagangles to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screw securing bottom jamb bracket to jamb, to maintain 5/8” spacing. Repeat for the right side.

JAMB

BRACKET

FLAGANGLE

5/16” X 1-5/8”

LAG SCREWS

VERTICAL

TRACK

ASSEMBLY

BOTTOM SECTION

WOODEN SHIMS

(IF NECESSARY)

VERITCAL TRACK

BOTTOM SECTION

ROLLER

JAMB BRACKET

5/8”

LAG

SCREW

LOCATIONS

QUICK INSTALL AND FULLY ADJUSTABLE

FLAGANGLE LAG LOCATIONS

QUICK INSTALL

LAG

SCREW

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Page 16

327985 NEW 9-04-06

Stacking Sections

Tools Needed:

Power Drill

7/16” Socket

Driver

NOTE: For door section identiﬁcation see page 4.

NOTE: Make sure hinge leafs are ﬂipped down, when stacking another section on top.

Place rollers in hinge tubes of the second section (lock section). With assistance, lift second section and guide rollers into the vertical tracks.

Align vertical marks in the upper alignment sticker, with the lower alignment sticker on right hand side on the back of door. Keep sections aligned and fasten hinges to connect the sections using 1/4” - 14 x 5/8” self-tapping screws. Repeat for other section(s) except top section.

IMPORTANT: WHEN SECURING THE END HINGES TO THE SECTIONS WITH 1/4”

- 14 X 5/8” SELF-TAPPING SCREWS, ENSURE THEY ARE ATTACHED AS SHOWN IN THE ILLUSTRATIONS ABOVE.

IMPORTANT: PUSH & HOLD THE HINGE LEAFS AGAINST SECTION WHILE SECURING WITH 1/4” - 14 X 5/8” SELFTAPPING SCREWS. END HINGES HAVE (2) SCREWS AND INTERMEDIATE HINGES HAVE (3) SCREWS.

NOTE: Install lock at this time (sold separately) see instructions in OPTIONAL SIDELOCK INSTALLATION on page 29.

LOCK SECTION

(2) 1/4” - 14 X 5/8”

SELF-TAPPING SCREWS

LEFT END HINGE

(3) 1/4” - 14 X 5/8” SELF-TAPPING SCREWS

INTERMEDIATE HINGE

(2) 1/4” - 14 X 5/8”

SELF-TAPPING SCREWS

ALIGNMENT

STICKERS

RIGHT END HINGE

(2) 1/4” - 14 X 5/8”

SELF-TAPPING SCREWS

END HINGES (LEFT HAND SHOWN, RIGHT HINGE SYMMETRICALLY OPPOSITE)

(3) 1/4” - 14 X 5/8”

SELF-TAPPING

INTERMEDIATE HINGES

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SCREWS

Page 17

Operator Bracket

U-BAR

Tools Needed:

Power Drill

7/16” Socket

Driver

NOTE: If installing a trolley type operator, complete this step. If not, skip this step and continue with step 10.

IMPORTANT: WHEN INSTALLING A

TROLLEY TYPE OPERATOR ON 9800 DOOR, A WAYNE-DALTON TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION. IT IS THEN UNNECESSARY TO FURTHER REINFORCE THE TOP SECTION OF THE MODEL 9800 WAYNE-DALTON DOOR, WHEN ATTACHING A TROLLEY TYPE OPERATOR, AS LONG AS THE INSTALLATION OF THE OPERATOR IS ACCORDING TO INSTALLATION INSTRUCTIONS AND OWNER’S MANUAL AND FORCE SETTINGS ARE ADJUSTED PROPERLY.

Remove, but retain (4-6) 1/4”-20 x 7/8” self drilling screws from the center of the u-bar, allowing the operator bracket to slide between the section and the u-bar.

SIDE VIEW OF U-BAR

1/4”-20 X 7/8” SELF

DRILLING SCREWS

OPERATOR

BRACKET

U-BAR

INSTALLATION

NOTE: For retro ﬁt applications, the

operator bracket must be aligned with an existing operator

Locate the center of the top section and slide operator bracket under u-bar till the operator bracket is seated against the u-bar ﬂange.

NOTE: Prior to fastening operator bracket to top section, ensure the top edge of operator bracket is aligned with the top edge of the section as shown on far right.

Attach the operator bracket using (6) 1/4” – 20 x 5/8” self drilling screws (as shown). Finish re-attaching the u-bar using the self tapping screws removed previously.

U-BAR

OPERATOR BRACKET IN

PLACE UNDER U-BAR

TOP OF SECTION

TOP EDGE OF

OPERATOR

BRACKET

U-BAR

OPERATOR

BRACKET

OPERATOR

BRACKET

SIDE VIEW OF U-BAR WITH

OPERATOR BRACKET INSTALLED

( 6) 1/4”-20 X 5/8”

SELF DRILLING

SCREWS

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Page 18

327985 NEW 9-04-06

Top Section

DOOR WIDTH

+3-3/8” TO 3-1/2”

Tools Needed:

Hammer

7/16” Socket

7/16” Wrench

Ratchet Wrench

7/16” Socket

Driver

Power Drill

Place the top section in the opening and vertically align with lower sections.

Align vertical marks in the upper alignment sticker, with the lower alignment sticker on right hand side on the back of door.

Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section.

Now ﬂip up hinge leafs, hold tight against section, and fasten center hinges ﬁrst, and end hinges last. (Refer to Step 8).

Position ﬂagangle between 1-11/16” (43 mm) to 1-3/4” (44 mm) from the edge of the door. Tighten the bottom lag screw. Flagangles must be parallel to the door sections. Repeat for opposite side.

ALIGNMENT STICKERS

IMPORTANT: THE DIMENSION BETWEEN THE FLAGANGLES MUST BE DOORWIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERATION.

For quick install track:

Complete the vertical track installation by securing the center jamb bracket(s) and tightening the other lag screws. Repeat for opposite side.

For fully adjustable track:

Complete the vertical track installation by securing the center jamb bracket(s) and tightening the other lag screws. Push the vertical track against the rollers so that the rollers are touching the deepest part of the curved side of the track (see illustration). Tighten all track bolts and nuts. Repeat for opposite side.

SECTION

CORRECT

SECTION

VERTICAL TRACK

NAIL

ROLLER

TOP

TOP SECTION

ROLLER AGAINST VERTICAL TRACK

FULLY ADJUSTABLE TRACK

1-11/16” TO 1-3/4”

TOP

SECTION

TOP

FLAGANGLE

INCORRECT

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Page 19

Attaching Horizontal Track to

Quick Install Flagangle

HORIZONTAL TRACK

FLAGANGLE

Tools Needed:

7/16” Socket

Ratchet Wrench

7/16” Wrench

Level

NOTE: If you have fully adjustable ﬂagangle, skip this step and complete Step 12.

To install horizontal track, align key slot of the horizontal track with the quick install tab of the ﬂagangle. Push curved portion of horizontal track down to lock in place.

Level horizontal track and bolt the top curve of the low headroom horizontal track slot in the ﬂagangle using (1) 5/16” washer, (1) 1/4”- 20 x 9/16” track bolt and (1) 1/4”- 20 ﬂange hex nut. Repeat for other side.

NOTE: If an idrive® opener will be installed, position horizontal tracks slightly above level.

NOTE: After completing this step, continue with Step 13.

QUICK

INSTALL

HORIZONTAL

TRACK

INSTALL

KEY SLOT

TAB

VERTICAL

TRACK

QUICK

TAB

FLAGANGLE

INSTALLATION

KEY SLOT

VERTICAL

TRACK

FLAGANGLE

(1) 5/16” WASHER

(1) 1/4”- 20

FLANGE HEX

NUT

(1) 1/4”- 20 X 9/16”

TRACK BOLT

TOP CURVE OF

LOW HEADROOM

HORIZONTAL TRACK

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Page 20

Attaching Horizontal Track to

Adjustable Flagangle

Tools Needed:

7/16” Socket

Ratchet Wrench

7/16” Wrench

Level

Flat Tip

Screwdriver

NOTE: If quick install ﬂagangle was installed in Step 11, skip this step and continue with Step 13. If not, complete this step.

To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track with the vertical track. Hand tighten the horizontal track to the ﬂagangle with (1) stud plate and (2) 1/4” - 20 ﬂange hex nuts.

Level horizontal track and bolt the top curve of the low headroom horizontal track slot in the ﬂagangle using (1) 5/16” washer, (1) 1/4”- 20 track bolt and (1) 1/4”- 20 ﬂange hex nut. Repeat for other side.

NOTE: If an idrive installed, position horizontal tracks slightly above level.

opener will be

FLAGANGLE

STUD

PLATE

1/4”-20 FLANGE

HEX NUTS

FLAGANGLE

(1) 5/16” WASHER

(1) 1/4”- 20

FLANGE

HEX NUT

(1) 1/4”- 20 X 9/16”

TRACK BOLT

TOP CURVE OF

LOW HEADROOM

HORIZONTAL TRACK

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Page 21

Top Brackets

TOP BRACKET

ASSEMBLY

Tools Needed:

Power Drill

7/16” Socket

Driver

Hammer

Remove, but retain (2-4) 1/4”- 14 x 7/8” self drilling screws from the right side of the u-bar, allowing enough room to slide the top bracket between the section and the u-bar.

Insert a roller into the low headroom top bracket. Slide the low headroom top bracket assembly between the u-bar and section, as shown.

Twist the roller into the upper track. Align the edge of the top bracket assembly parallel to the section edge. Secure the top bracket and u-bar to the section with (3) 1/4”- 20 x 7/8” self drilling screws through the upper and lower slots of the bracket, as shown.

Finish re-attaching the u-bar using the 1/4”- 20 x 7/8” self drilling screws removed previously. Repeat for left hand side.

Remove the nail that was temporarily holding the top section in place.

TOP SECTION

TOP BRACKET

ASSEMBLY

(3) 1/4”-20 X 7/8” SELF

DRILLING SCREWS

INSTALLATION

IMPORTANT: FAILURE TO REMOVE NAIL

BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION.

WARNING

DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR, AS OUTLINED IN STEP 21, OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY.

HEADER

TOP SECTION

TOP BRACKET

ASSEMBLY

SECTION EDGE

TOP SECTION

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Page 22

End Brackets

LEFT HAND END

BRACKET

Tools Needed:

Power Drill

7/16” Socket

Driver

NOTE: Right and left hand is always determined from inside the garage looking out.

End bearing brackets are right and left. Align bottom edge of left end bracket with the top edge of the ﬂagangle. Maintaining this alignment, also align the right edge of the end bracket with the right edge of the ﬂagangle.

Secure end bracket to the jamb using (3) 5/16” x 1-5/8” lag screws as shown. Repeat for the other side.

TOP SECTION

(3) 5/16” X 1-5/8”

LAG SCREWS

LEFT HAND END

BRACKET

TOP SECTION

MOUNTING SURFACE

Center Bearing Bracket

Tools Needed:

Power Drill

7/16” Socket

Driver

Level

Tape Measure

Pencil

1/4” Torx Bit

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Measure to locate the center of the door and mark a vertical pencil line on the mounting surface above the door, to indicate the center line of the door. Then, measure from the center of the bearing, in one of the end bearing brackets, DOWN to the top of the door. Using that dimension, measure UP from the top of the door and mark a horizontal pencil line on the mounting surface, intersecting the vertical pencil line. Now align the edge of the center bearing bracket along the vertical pencil line on the mounting surface. Center the bearing bracket on the horizontal line. This will ensure the torsion tube is level between the center and end bearing brackets. Attach the center bearing bracket, in this location, to the mounting surface, using (2) 5/16” x 1-5/8” lag screws and (1) 5/16” x 2” tamper-resistant lag screw. IMPORTANT: USE THE 5/16” X 2” TAMPERRESISTANT LAG SCREW ONLY IF MOUNTING SURFACE MOUNTED OVER MASONRY. TAMPER-RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BEARING BRACKET.

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(1) 5/16” X 1-5/8” LAG SCREW

TAMPER-RESISTANT LAG

EQUAL DISTANCE

CENTER OF

END BEARING

BRACKET

MOUNTING SURFACE

HORIZONTAL LINE

(1) 5/16” X 2”

SCREW

CENTER BEARING

BRACKET

VERTICAL LINE

HORIZONTAL LINE

VERTICAL

CENTER BEARING BRACKET

LINE

Page 23

Torsion Spring Assembly

RIGHT HAND

CABLE DRUM

BLACK

Tools Needed:

none

NOTE: Right and left hand is always determined from inside the garage looking out.

Facing the inside of the door, lay the torsion tube on the ﬂoor. Lay the spring with the black color coded winding cone and the red color coded cable drum, at the left hand end of the tube. Lay the spring with the red color coded winding cone and the black color coded cable drum, at the right hand end of the tube.

NOTE: Identify the springs provided as either right hand wound (red winding cone), which goes on the RIGHT HAND SIDE or left hand wound (black winding cone), which goes on the LEFT HAND SIDE.

NOTE: The set screws used on all torsion counterbalance winding cones and cable drums, are now colored red. DO NOT identify right and left hand by the set screw color.

LEFT HAND

CABLE DRUM

RED

LEFT HAND WOUND

BLACK WINDING CONE

LEFT HAND WOUND BLACK

WINDING CONE LEFT HAND SIDE

NYLON CENTER

BRACKET BUSHING

LEFT HAND SIDE

RIGHT HAND WOUND RED

WINDING CONE RIGHT HAND SIDE

TORSION

TUBE

TORSION

NYLON CENTER

BRACKET BUSHING

RIGHT HAND WOUND

RED WINDING CONE

RIGHT HAND SIDE

TUBE

INSTALLATION

Slide the nylon center bushing onto the torsion tube followed by the springs. The nylon center bushing and springs must be positioned as shown.

With assistance, pick up the torsion assembly and slide one end of the tube through one end bearing bracket. Lay the torsion tube into the center bearing bracket and slide the other end of the tube into the opposite end bearing bracket.

Position the torsion tube so that equal amounts of the tube extend from each end bearing bracket.

Slide the red cable drum onto the left end of the torsion tube. Slide the black cable drum onto the right end of the torsion tube.

TORSION

ASSEMBLY

END

BEARING

BRACKET

CENTER

BRACKET

TORSION

ASSEMBLY

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Page 24

Tools Needed:

1/2” Wrench

Nylon Center Bushing

Slide the nylon center bushing into the stationary spring cone at the end of the spring and align the stationary spring cones with the holes in the center bearing bracket. Secure the springs to the center bearing bracket with (2) 3/8”-16 x 1-1/2” hex head bolts and (2) 3/8”-16 nuts.

STATIONARY

SPRING CONE

CENTER BEARING

BRACKET

TORSION SPRING

STATIONARY

SPRING CONE

IMPORTANT: SPRINGS UNDER TENSION CAN BE DANGEROUS.

IMPORTANT: THE SPRING WARNING TAG(S) SUPPLIED MUST BE SECURELY ATTACHED TO THE STATIONARY SPRING CONE IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING WARNING TAG BE REQUIRED, CONTACT WAYNE-DALTON CORP. FOR FREE REPLACEMENTS.

TORSION

SPRING

TORSION SPRING

NYLON CENTER

BUSHING

SPRING

WARNING TAG

CENTER BEARING

BRACKET

(1) 3/8”-16 NUT

(1) 3/8”-16 X 1-1/2”

HEX HEAD BOLT

(1) 3/8”-16 NUT

(1) 3/8”-16 X 1-1/2”

HEX HEAD BOLT

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TORSION SPRING

Page 25

LEFT CABLE DRUM

Counterbalance Cables

Tools Needed:

Vice Grips

3/8” Wrench

Release the vice grips from the ends of the cables and thread the counterbalance cables around the back side of the left cable drum and verify that there is no cable obstructions. Hook the cables into the drums. Slide the left hand cable drum against the left hand end bearing bracket and tighten the set screws in the drum to 14-15 ft. lbs. of torque (Once set screws contact the tube, tighten screws one full turn). Rotate the left hand drum and torsion tube until cable is taut. Attach vice grips to torsion tube and brace vice grips against jamb to keep cable taut. Slide the right hand cable drum against the right hand end bearing bracket and rotate drum until cable is taunt. Tighten set screws in right hand cable drum.

IMPORTANT: CHECK EACH CABLE, MAKING SURE BOTH ARE SEATED PROPERLY ON THE CABLE DRUMS AND HAVE EQUAL CABLE TENSION.

CABLE

LEFT END BEARING BRACKET

CABLE IN POSITION

SET

SCREWS

CABLE

HOOKED IN

CABLE DRUM

JAMB

VICE GRIPS

TORSION

TUBE

LEFT CABLE

DRUM

INSTALLATION

Tools Needed:

Vice Clamp

Securing Door

for Spring Winding

Place vice clamps onto both vertical tracks just above the third Roller. This is to prevent the garage door from raising while winding torsion spring(s).

WARNING

FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.

PLACE VICE CLAMPS

ABOVE 3RD ROLLER ON

BOTH VERTICAL TRACKS

VICE CLAMPS

ATTACHED TO

INNER RAIL

OF TRACK

TRACK

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Page 26

Winding Torsion Spring(s)

Tools Needed:

Power Drill

3/16” Drill Bit

7/16”

Socket Driver

Phillips Head

Screwdriver

Position a ladder slightly to the side of spring so that the winding cone is easily accessible, yet your body is not in direct line with the winding bars. Check the label attached to the spring warning tag for the required number of complete turns to balance your door.

8’0” Door Height = Approx 8-3/4 Turns

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. Alternately inserting the winding bars into the holes of the spring’s winding cone, rotate the winding cone upward toward ceiling, 1/4 turn at a time, until the required number of complete turns for your door height is achieved. As the last 1/4 turn is achieved, securely hold winding bar while tightening both set screws in winding cone to 14-15 ft. lbs. of torque (Once set screws contact the tube, tighten screws one full turn). Carefully remove winding bar from winding cone. Repeat for the opposite spring. While holding the door down, to prevent it from rising unexpectedly, in the event the spring(s) were overwound, carefully remove the locking clamps from the torsion tube and the vertical tracks.

TORSION

TUBE

SET

SCREWS

SPRING

WINDING

CONE

APPROVED

WINDING BARS

IMPORTANT: CAUTIOUSLY REMOVE LOCKING PLIERS FROM THE TORSION TUBE AND LOCKING CLAMPS FROM THE VERTICAL TRACKS. Adjustments to the required from the number of turns stated may be necessary. If door raises off floor under spring tension alone, Reduce spring tension until door rests on the floor. If the door is hard to raise or drifts down on its own, add spring tension. An unbalanced door such as this can cause garage door opener operation problems.

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TORSION

TUBE

WINDING

CONE

APPROVED

WINDING BARS

SPRING

Page 27

Tools Needed:

Ratchet Wrench

1/2” Socket

1/2” Wrench

(2) Vice Clamps

Rear Support

DOOR IN PARTIALLY

OPEN POSITION

WARNING

KEEP HORIZONTAL TRACK PARALLEL AND WITHIN 3/4” MAXIMUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN SEVERE INJURY OR DEATH.

Level

Hammer

Tape Measure

Raise the door until the top section and half of the next section are in a horizontal position. Do not raise door any further since the horizontal track are not yet supported at the rear.

WARNING

RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE INJURY OR DEATH.

Clamp a pair of vice clamps on the vertical tracks just above the second roller on one side, just below the second roller on the other side. This will prevent the door from raising or lowering while installing the rear support.

Using perforated angle, 5/16” x 1-5/8”hex head lag screws and 5/16” bolts with nuts (may not be supplied), fabricate rear support for horizontal tracks. Attach horizontal tracks to the rear supports with 5/16”-18 x 1-1/4” hex bolts and nuts (may not be supplied). Horizontal tracks must be level and parallel with door.

VICE

CLAMPS

INSTALLATION

VERTICAL

TRACK

NOTE: If rear supports are to be installed over drywall, use 5/16” x 2” hex head lag screws.

Adjust weather seal or door stop (if necessary). Now permanently attach the weather seal or door stop to both door jambs and header. (They were temporarily attached in PREPARING THE OPENING on page 10.) Avoid pushing weather seal or door stop too tightly against face of door.

DOOR EDGE

HORIZONTAL

TRACK

3/4”

WARNING

PRIOR TO WINDING OR MAKING

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Page 28

Tools Needed:

Rear Support

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.

Now, lift door and check it’s balance. Adjust, if door lifts by itself (hard to pull down) or if door is difﬁcult to lift (easy to pull down). Loosen set screws before adjusting the number of turns of spring tension. To adjust spring(s), only add or remove 1/4 turn on the springs at a time. Adjust both sides equally. Tighten set screws once adjustments have been completed.

SOUND FRAMING MEMBERS

ANGLE BRACE

HORIZONTAL TRACK

SOUND FRAMING MEMBERS

PERFORATED ANGLE BOLTED USING (2) 5/16” X 1-5/8” HEX HEAD LAG

SCREWS TO CEILING

MEMBER AND PARALLEL

TO DOOR

BOLT MUST EXTEND INTO

THE TRACK TO SERVE AS

A ROLLER STOP

IMPORTANT: DO NOT ADD OR REMOVE

MORE THAN 1 SPRING TURN FROM SPECIFIED AMOUNT. IF THE DOOR STILL DOES NOT OPERATE EASILY, LOWER THE DOOR TO THE CLOSED POSITION, UNWIND SPRING(S) TO ZERO, AND RECHECK THE FOLLOWING ITEMS:

1.) Check the door for level.

2.) Check the torsion spring tube and ﬂagangles for level and plumb.

3.) Check the distance between the ﬂagangles - must be door width plus 3-3/8” to 3-1/2”.

4.) Check the counterbalance cables for equal tension - adjust if necessary.

5.) Rewind the spring(s).

6.) Make sure door isn’t rubbing on jambs.

ANGLE BRACE

HORIZONTAL TRACK

(3) 5/16” BOLTS & NUTS

PERFORATED ANGLE

BOLTED USING (2) 5/16”

X 1-5/8” HEX HEAD LAG

SCREWS TO CEILING

MEMBER AND PARALLEL

TO DOOR

BOLT MUST EXTEND INTO

THE TRACK TO SERVE AS

A ROLLER STOP

PERFORATED ANGLE

WEATHER

SEAL

JAMB

PERMANENTLY ATTACHED

WEATHER SEAL

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Page 29

Side Lock

Tools Needed:

Power Drill

7/16” Socket

Driver

Tape Measure

Install the side 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 side lock should be spaced in approximately 1/8” from the section edge.

IMPORTANT: SIDE LOCKS MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION, IF AN OPERATOR IS INSTALLED ON THE DOOR.

NOTE: After completing this step, continue with step 9 on page 17.

(4) 1/4”- 20 X 11/16”

SELF DRILLING SCREWS

1/8”

Tools Needed:

Power Drill

1/8” Drill Bit

Pull Rope

WARNING

DO NOT INSTALL PULL ROPES ON DOORS WITH ELECTRIC 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 rope to the No. 6 screw eye and to the bottom bracket as shown.

NO. 6 SCEW EYE

PULL ROPE

OPTIONAL INSTALLATION

BOTTOM BRACKET

PULL ROPE

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Page 30

Trolley Operator

Tools Needed:

WARNING

OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR. FAILURE TO ADJUST OPERATOR, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY. IF YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM, THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED. FAILURE TO MAKE ADJUSTMENTS, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY.

1. Install operator rail 1/2” to 1” (13 - 38 mm) above high arc of top section of the door.

SUITABLE

MOUNTING

SURFACE 2 X 6

LUMBER MINIMUM

HEADER

OPERATOR RAIL

DOOR ARM TO OPERATOR BRACKET

OPERATOR

RAIL

PERFERATED

ANGLE

2. Mount operator to ceiling so that 1” to 1-1/2” (25 - 38 mm) clearance is maintained between trolley rail and top section when door is fully open (trolley rail will slope down towards rear).

3. Attach door arm to operator bracket installed in Step 9.

4. Attach operator rail to suitable mounting surface 2 x 6 lumber minimum.

5. Attach operator to ceiling using perforated angle.

IMPORTANT: ANGLES MUST BE SECURELY ATTACHED TO SOUND FRAMING MEMBER(S).

OPERATOR

FRAMING MEMBERS

PERFERATED ANGLE

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Page 31

Cleaning Your Steel And Fiberglass Garage Door

IMPORTANT: DO NOT USE A PRESSURE WASHER ON 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.

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

NOTES: Be sure to clean behind weather stripping on both sides and top of door.

CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

GLASS CLEANING INSTRUCTIONS

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

ACRYLIC CLEANING INSTRUCTIONS

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

NOTE: DO NOT USE any window cleaning ﬂuids, scouring compounds, gritty cloths or solvent-based cleaners of any kind.

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MAINTENANCE

Page 32

Steel Preparation For Painting

STEEL (SURFACE PREPARATION FOR PAINTING)

Wax on the surface must be removed or paint peeling/ﬂaking will result. To remove this wax, it will be necessary to lightly scuff the surface with a ﬁne steel wool pad, saturated with soapy water. A ﬁnal wipe and rinse should be done with clean water only, to remove any loose particles and any soapy ﬁlm residue.

Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or No. 400 sand paper to create a smoother surface. Care must be taken to not expose the substrate under the paint. Once the substrate is exposed, the likelihood for rusting is greatly increased.

If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed area lightly and paint with a high quality metal primer, speciﬁcally intended for galvanized surfaces, to protect the area from corrosion. Allow for drying time on primer can label before applying topcoat.

The surface of the factory-applied ﬁnish, that is being painted, must not be too smooth, or the paint will not adhere to it. It is advisable to test in an inconspicuous area, to evaluate adhesion. If poor adhesion is observed, surface preparation for painting the factory-applied ﬁnish must be repeated until desired results are achieved. Again, care must be taken to not expose the substrate under the paint.

STEEL (PAINTING)

After surface has been properly prepared, it must be allowed to dry thoroughly, and then coated immediately with premium quality latex house paint. Follow paint label directions explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate is exposed and not properly primed, painting with latex paint may cause accelerated rusting of the steel in the exposed area.

NOTES:

This Limited Warranty will be voided if the original ﬁnish is painted over, unless Manufacturer’s preparation and painting instructions are followed

explicitly.

2. Consult a professional coatings contractor if in doubt about any of the above directions.

3. Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers. Pay particular attention to acceptable weather and temperature conditions in which to paint.

Fiberglass Refinishing And Or Finishing

Reﬁnishing

The top coat on factory ﬁnished door may require a re-coat after 1-3 years if the surface appears chalky or faded. Reapply a top coat as follows: (Always test on a small area prior to top coating the entire door)

1. Clean surfaces with soap and water, mineral spirits or naptha.

NOTE: Light scufﬁng of surface may be required using Scotch-Brite™ pads.

2. Apply a commercial brand of exterior grade top coat following the manufacturer instructions.

Finishing

It is recommended that the door be purchased pre-ﬁnished due to the size of the door, the required spray equipment and the quality problems that could result. Wayne-Dalton assumes no liability for non-factory ﬁnished doors. If ﬁnishing is performed, use exterior commercial grade ﬁnishing kits approved for use on ﬁberglass or commercially available exterior grade water based or oil based paint. The customer assumes all liability for the ﬁnishing.

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Page 33

Lifetime Limited Warranty

Model 9800

Subject to the terms and conditions contained in this Lifetime Limited Warranty, Wayne-Dalton Corp. (“Manufacturer”) warrants the sections of the door for as long as you own the door with the exception of the items that follow which is described at the top of this page. These exceptions will be warranted for a period of THREE (3) YEARS from the date of installation against:

(i) Delamination of the ﬁberglass skin or peeling of the original factory-applied coating on the door as a result of a defect in the original ﬁberglass skin where the door sections and the original ﬁberglass skin and factory-applied coating: (a) have not been subjected to adverse atmospheric conditions or contaminates (such as salt water or other marine environment, or to toxic or abrasive substances, including those in the air); (b) have been maintained in compliance with Manufacturer’s recommendations; and (c) have not been subject to physical abrasion, impacted by a hard objects, or have been punctured.

(ii) The door becoming inoperable due to rust-through of the steel skin backer from the core of the door section, caused by cracking, splitting, or other deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.

(iii) Peeling, cracking, chalking or fading of the factory-applied coating, from the time of installation. If the door is re-stained or re-painted, the warranty for the factory-applied coating is void.

The Manufacturer warrants the garage door hardware (except springs) and the tracks of the above-described door, for as long as you own the door, against defects in material and workmanship, subject to all the terms and conditions below. The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Lifetime Limited Warranty against defects in material and workmanship for a period of ONE (1) YEAR from the date of installation. After a period of TWENTY (20) YEARS, from time of installation, replacement of Lifetime Limited Warranty materials will be pro-rated at 50 per cent of Manufacturer’s published list pricing at time of claim, and you must pay this amount. This Limited Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as his/her primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or to installations on rental property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the premises is sold), nor does it extend beneﬁts to any other person. As a result this Limited Warranty does NOT apply to any person who purchases the product from someone other than an authorized Wayne-Dalton dealer or distributor. The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its components, abuse, damage from corrosive fumes or substances, salt spray or saltwater air, ﬁre, Acts of God, failure to properly maintain the door, or attempt to use the door, its components or related products for other than its intended purpose and its customary usage. This Limited Warranty does not cover ordinary wear. This Limited Warranty will be voided if any holes are drilled into the door, other than those speciﬁed by the Manufacturer. THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS ACT. NO WARRANTIES, EXPRESS OR IMPLIED (INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY, ABOVE.

  • SomeStatesdonotallowlimitationsonhowlonganimpliedwarrantylasts,sotheabovelimitationsmaynotapplytoyou.

Any claim under this Limited Warranty must be made in writing, within the applicable warranty period, to the dealer from which the product was purchased. Unless the dealer is no longer in business, a written claim to the Manufacturer will be the same as if no claim had been made at all. At the Manufacturer’s option, pursuant to the dealer having notiﬁed the Manufacturer of a warranty claim, a service representative may inspect the product on site, or Buyer may be required to return the product to the Manufacturer at Buyer’s expense. Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation. If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty, the Manufacturer will cause the defective product to be repaired or replaced. The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer, subject to applicable law. THE REMEDY WILL COVER ONLY MATERIAL. THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES, SUCH AS FIELD SERVICE LABOR FOR REMOVAL, INSTALLATION, PAINTING, SHIPPING, ETC. Any repairs or replacements arranged by Manufacturer will be covered by (and subject to) the terms, conditions, limitations and exceptions of this Limited Warranty; provided, however, that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed, and this Limited Warranty will expire at the same time as if there had been no defect. If a claim under this Limited Warranty is resolved in a manner other than described in the immediately preceding paragraph, then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product. THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy. The liability of the Manufacturer, whether in contract or tort, under warranty, product liability, or otherwise, will not go beyond the Manufacturer’s obligation to repair or replace, at its option, as described above. THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, including (but not limited to) damage or loss of other property or equipment, personal injury, loss of proﬁts or revenues, business or service interruptions, cost of capital , cost of purchase or replacement of other goods, or claims of third parties for any of the foregoing.

 • 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. No employee, distributor, dealer, representative, or other person has the authority to modify any term or condition contained in this Limited Warranty or to grant any other warranty on behalf of or binding on the Manufacturer, and anyone’s attempt to do so will be null and void. Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer. The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio, USA, to the extent permitted by law.

 • ThisLimitedWarrantygivesyouspeciclegalrightsandyoumayalsohaveotherrights,whichmayvaryfromStatetoState.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer.

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MAINTENANCE

Page 34

Thank you for your purchase

www.wayne-dalton.com

Covered by one or more of the following Patents; 5,408,724; 5,409,051; 5,419,010; 5,495,640; 5,522,446; 5,562,141; 5,566,740; 5,568,672; 5,718,533; 6,019,269; 6,089,304; 6,644,378; 6,374,567; 6,561,256; 6,527,037; 6,640,872; 6,672,362; 6,725,898; 6,843,300; 6,915,573; 6,951,237; 7,014,386; 7,036,548; 7,059,380; 7,121,317; 7,128,123; 7,134,471; 7,134,472; 7,219,392; 7,254,868. Canadian: 2,384,936; 2,477,445; 2,495,175; 2,507,590; 2,530,701; 2,530,74; 2, 2,532,824. Other US and Foreign Patents pending.

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Wayne-Dalton 341785 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual