Wayne-Dalton 9800 User Manual

Page 1
T a b l e O f C o n t e n t s
GARAGE DOORS & OPENERS
9800
t o r s i o n
Front Mount Low HeadrooM
MH
instaLLation instructions and owners ManuaL
Parts Breakdown 2 Pre-Installation 3
Important Safety Instructions 3 Tools Required 3 Package Contents 3 Door Section Identification 4 Removing an Existing Door 4 Preparing the Opening 4
Installation 6 Optional Installation 14
Door Arm Hookup 14 Inside Lock 14 Pull Down Rope 14
Maintenance 15
Cleaning Your Garage Door 15 Painting Your Garage Door 15 Fiberglass Refinishing and Finishing 15 Operation and Maintenance 15
Warranty 17 Dealer Locator Information 18
©Copyright 2011 Wayne-Dalton, a Division Of Overhead Door Corporation
IMPORTANT NOTICES!
Wayne-Dalton highly recommends that you read and fully under­stand the Installation Instructions and Owner’s Manual before you attempt this installation.
To avoid possible injury, read the enclosed instructions carefully before installing and operating the garage door. Pay close attention to all warnings and notes. After installation is complete, fasten this manual near garage door for easy reference.
The complete Installation Instructions and Owner’s Manual are available at no charge from: Wayne-Dalton, a Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, Or Online At www.Wayne-Dalton.com
Part No.
345571 REV4 03/18/2011
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J3.
PARTS BREAKDOWN
NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations.
J1.
J5.
J3.
J4.
C1.
A1.
J6.
B2.
B1.
A2.
I3.
F1.
D2.
D1.
L1.
C2.
F2.
F3.
D4.
D3.
C1.
J5.
E4.
E1.
E2.
E3.
J2.
K1.
F1.
F2.
F3.
J4.
J6.
C1.
I1.
L2.
G1.
A1.
A2.
G2.
H2.
H1.
B2.
Top of vertical
B1.
I4.
track
3rd hole set
2nd hole set
1st hole set
I2.
B2. (Quick
Install
Feature)
Top
hole
Middle
hole
Bottom
hole
Top of vertical track
3rd hole set
2nd hole set
1st hole set
K2.
B1. (Fully
Adjustable
Feature)
Lower hole of hole/ slot pattern
A. FLAGANGLES:
A1. Fully Adjustable (F.A.) Flagangles A2. Quick Install (Q.I.) Flagangles
B. JAMB BRACKETS:
B1. Fully Adjustable (F.A.) Jamb Brackets B2. Quick Install (Q.I.) Jamb Brackets
C. TRACK ROLLERS:
C1. Short Stem Track Rollers C2. Long Stem Track Rollers
D. GRADUATED END HINGES:
D1. Single Graduated End Hinges (S.E.H.), Anti-Pinch D2. Single Graduated End Hinges (S.E.H.), Industry Standard D3. Double Graduated End Hinges (D.E.H.), Anti-Pinch D4. Double Graduated End Hinges (D.E.H.), Industry Standard
E. STACKED SECTIONS:
E1. Top Section E2. Intermediate(s) Section E3. Lock Section E4. Bottom Section
F. TOP FIXTURE ASSEMBLIES:
F1. Top Fixture Assemblies – For Models 9600/9400/9100/5140/5120 F2. Top Fixture Assemblies – For Model 9700 F3. Top Fixtures – For Model 9800
G. STRUT(S):
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
G1. Strut (U-shaped) G2. Strut (A-symmetrical)
H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):
H1. Drawbar Operator Bracket – For Models 9600/9400/9100/5140/5120 H2. Drawbar Operator Bracket – For Models 9700/9800
TRACKS:
I1. Left Hand Horizontal Track Assembly I2. Right Hand Horizontal Track Assembly I3. Left Hand Vertical Track I4. Right Hand Vertical Track
J. TORSION SPRING ASSEMBLY:
J1. Center Bracket Bushing Assembly J2. Torsion Shaft J3. End Bearing Brackets J4. Right Hand and Left Hand Cable Drums J5. Right Hand and Left Hand Torsion Springs (As Required) J6. Counterbalance Lift Cables
K. REAR BACK HANGS:
K1. Left Hand Rear Back Hang Assemblies K2. Right Hand Rear Back Hang Assemblies
L. BOTTOM CORNER BRACKETS (AS REQUIRED):
L1. Left Hand Bottom Corner Bracket L2. Right Hand Bottom Corner Bracket
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Pre-Installation
Important Safety Instructions
DEFINITION OF KEY WORDS USED IN THIS MANUAL:
WARNING WARNING
INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH; IF NOT AVOIDED, COULD RESULT IN SEVERE OR FATAL INJURY.
CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT FROM FAILURE TO FOLLOW
INSTRUCTIONS.
IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION. NOTE: Information assuring proper installation of the door.
READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUESTION ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN DO THE INSTALLATION OR REPAIRS.
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 caus-
ing 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 neces-
sary 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 altera-
tion to any part of the door, especially to springs, spring brackets, bottom corner brackets, fasteners, counterbalance lift cables or supports. To avoid possible severe or fatal injury, have any such work performed by a trained door systems technician using proper tools and instructions.
12. On electrically operated doors, pull down ropes must be removed and locks must be
removed or made inoperative in the open (unlocked) position.
13. Top section of door may need to be reinforced when attaching an electric opener. Check
door and/ or opener manufacturer’s instructions.
14. Visually inspect door and hardware monthly for worn and or broken parts. Check to
ensure door operates freely.
15. Test electric opener’s safety features monthly, following opener manufacturer’s instruc-
tions.
16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks. Track
systems are not intended or designed to support extra weight.
17. This door may not meet the building code wind load requirements in your area. For your
safety, you will need to check with your local building official for wind load code require­ments and building permit information.
After installation is complete, fasten this manual near the garage door. IMPORTANT: STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN
INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, DRAWBAR OP­ERATOR MOUNTING/ SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT2000 LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.
NOTE: It is recommended that 5/16” lag screws are pilot drilled using a 3/16” drill bit, prior to fastening.
IMPORTANT: WHEN INSTALLING 5/16” LAG SCREWS USING AN ELECTRIC DRILL/ DRIVER, THE DRILL/ DRIVERS CLUTCH MUST BE SET TO DELIVER NO MORE THAN 200 IN-LBS OF TORQUE. FASTENER FAILURE COULD OCCUR AT HIGHER SETTINGS.
Tools Required
• Power drill
• Drill bits: 1/8”, 3/16”, 9/32”, 7/16”, 1/2”
• Ratchet wrench
• Socket driver: 7/16”
• Sockets: 7/16”, 1/2”, 9/16”, 5/8”
• Phillips head screwdriver
• Locking Pliers
• (2) Vice clamps
• Wrenches: 3/8”, 7/16”, 1/2”, 9/16”, 5/8”
• 1/4” Torx bit
• Approved winding rods
• Hammer
• Tape measure
• Step Ladder
• Level
• Pencil
• Leather gloves
• Safety glasses
Package Contents
NOTE: Depending on the door model, some parts listed will not be supplied if not required. Rear Back Hangs may not be included with your door.
Door sections (as required)
Torsion shaft
Q.I. flag angles RH/LH (as required)
Q.I. jamb brackets
(as required)
Cable drums RH/LH
F.A. jamb brackets
Bottom corner brackets
RH/LH (as required)
(as required)
Center bracket
F.A. flag angles RH/LH (as required)
Vertical tracks RH/LH
Horizontal tracks RH/LH
Weather seals & nails
(If included)
(2) Top fixtures
Center bracket
bracket (if included)
bushing
Door stop & nails
(If included)
Drawbar operator
(2) End bearing
brackets
WARNING WARNING
PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, ENSURE YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTAL­LATION INSTRUCTIONS. OTHERWISE, THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY.
IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING
LOOKING OUT
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
Torsion springs RH/LH
Pull down rope
(if included)
Track rollers
1/4”-20 x 7/8” Self
drilling screws (as required)
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Page 4
Warning label
5/16” x 1 5/8” Hex head lag screws
1/4”-14 x 5/8” Self tapping
screws (as required)
1/4”-20 x 9/16”
Track bolts (as required)
(2) 3/8”-16 x 3/4”
Truss head bolts
(as required)
1/4”-20 x 5/8”
Tamper resistant Self
drilling screws (as required)
Clevis pins
1/4”- 20 Flanged
hex nuts (as required)
5/16” x 2” Tamper-resistant hex head
1/4”-20 x 11/16” Self
drilling screws (as required)
(2) 3/8”- 16 Hex nuts
5/16” Washers
Cotter pins
lag screw (as required)
3/8”-16 x 1-1/2” Hex bolts
Door Section Identification
Graduated end and center hinges are always pre-attached at the top of each section (except top section) and the graduated end hinges are stamped for identification, #1, #2, #3, and #4 (#4 only on five section doors). 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. If the stamp on the graduated end hinge is illegible, refer to the section side view illustration. The section side view illustration shows the graduated end hinge profile of all sections, and can also be used to identify each section.
The BOTTOM SECTION can be identified by #1 graduated end hinges, the factory attached bottom astragal, the factory attached bottom corner brackets and by the bottom corner bracket warning labels on each end stile.
The LOCK SECTION can be identified by #2 graduated end hinges on a 4 section high door and by #3 graduated end hinges on a 3 section high door. Also, on a 3 section door, the lock section will come with a warning label attached to the right or left endstile.
The INTERMEDIATE SECTION can be identified by #3 graduated end hinges (Only on a 4 section high door). The section will have a warning label attached to either the right or left hand end stile.
NOTE: #4 graduated end hinges are used on the fourth section of five section doors. The TOP SECTION can be identified with no pre-installed graduated end or center hinges.
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
Top section
#3
Warning labels (Only on a 4 Section High Door)
Intermediate section
#2
Warning labels (Only on a 3 Section High Door)
Lock section
#1
Bottom corner bracket warning labels
Astragal
Bottom section
Typical graduated end hinge stamping location
1-3/8”
#3 Graduated end hinge
1-1/8”
#2 Graduated end hinge
7/8”
#1 Graduated end hinge
Bottom corner bracket
Astragal
Section side view illustration
Removing an Existing Door
IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.
WARNING WARNING
A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR SYSTEMS TECH­NICIAN, USING PROPER TOOLS AND INSTRUCTIONS, RELEASE THE SPRING TENSION.
For detailed information see supplemental instructions “Removing an Existing Door/ Preparing the Opening”. These instructions are not supplied with the door, but are available at no charge from Wayne-Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at www.Wayne-Dalton.com.
Preparing the Opening
IMPORTANT: IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A NEW DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING.
To ensure secure mounting of track brackets, side and center brackets, or steel angles to new or retro-fit construction, it is recommended to follow the procedures outlined in DASMA technical data sheets #156, #161 and #164 at www.dasma.com.
The inside perimeter of your garage door opening should be framed with wood jamb and header material. The jambs and header must be securely fastened to sound framing members. It is recommended that 2” x 6” lumber be used. The jambs must be plumb and the header level. The jambs should extend a minimum of 12” (305 mm) above the top of the opening for Torsion counterbalance systems. For low headroom applications, the jambs should extend to the ceiling height. Minimum side clearance required, from the opening to the wall, is 3-1/2” (89 mm).
IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE REPLACED.
For Torsion counterbalance systems, a suitable mounting surface (2” x 6”) must be firmly at­tached to the wall, above the header at the center of the opening.
NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting the lumber. Do not attach the mounting surface with nails.
WEATHERSTRIPS (MAY NOT BE INCLUDED):
Depending on the size of your door, you may have to cut or trim the weatherstrips (if necessary) to properly fit into the header and jambs.
NOTE: If nailing product at 40°F or below, pre-drilling is required. NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.
For Quick Install track: For the header, align the weatherstrip with the inside edge of the header and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and flush with the inside edge of the jamb. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the
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opening during installation. Equally space nails approximately 12” to 18” apart. For Fully Adjustable track: For the header, align the weatherstrip 1/8” to 1/4” inside the header
edge, and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and 1/8” to 1/4” inside the jamb edge. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.
Headroom requirement: Headroom is defined as the space needed above the top of the door for tracks, springs, etc. to allow the door to open properly. If the door is to be motor operated, 2-1/2” (64 mm) of additional headroom is required.
NOTE: 6” low headroom conversion kit is available for 12” radius only. Contact your local Wayne-Dalton dealer.
Backroom requirement: Backroom is defined as the distance needed from the opening back into the garage to allow the door to open fully.
BACKROOM REQUIREMENTS
Door Height Track Manual Lift Motor Operated
6’0” to 7’0” 6” Low Headroom 102” (2591 mm) 125” (3175 mm)
7’1” to 8’0” 6” Low Headroom 114” (2896 mm) 137” (3480 mm)
HEADROOM REQUIREMENTS
Track Type Space Needed
6” Low Headroom 9” (229 mm)
Min. Side
Suitable mounting surface 2”x 6” lumber minimum
Header board 2”x 6” lumber preferred
Headroom
room Clearance is 3 1/2”
Backroom
Min. Side room Clearance is 3 1/2”
Weatherstrips
Plumb jambs
Finished
Jambs
Level header
Finished
Height
Door width
Door
Nail
Jamb
Jamb
Quick Install track
Jamb
Jamb
Fully Adjustable track
1/8” to 1/4”
1/8” to 1/4”
Weather seal
Door Stop
Weather seal
Door Stop
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
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Page 6
INSTALLATION
1st hole set
Vertical track
Top of track
2nd hole set 3rd hole set
Before installing your door, be certain that you have read and followed all of the instruc­tions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door.
NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.
Quick Install Flag Angles
1
NOTE: If you have Fully Adjustable flag angles, skip this step. NOTE: If you have riveted track, skip this step. NOTE: Flag angles are right and left handed.
Place the lower Quick Install tab of the left hand flag angle in the Quick Install feature of the left hand vertical track. Give the flag angle 1/4 turn to lock in place. Repeat for other side.
Tools: None
Vertical track
Flag angle
Lower Quick Install tab
Quick Install feature
1/4 Turn
Fully Adjustable Flag Angles
2
NOTE: If you have Quick Install flag angles, skip this step. NOTE: If you have riveted track, skip this step. NOTE: Flag angles are right and left handed.
If you have Quick Install vertical tracks, hand tighten the left hand flag angle to the left hand vertical track using (1) stud plate and (2) 1/4” – 20 flange hex nuts. Repeat for the other side.
If you have Fully Adjustable vertical tracks, hand tighten the left hand flag angle to the left hand vertical track using (2) 1/4”-20 x 9/16” track bolts and (2) 1/4”-20 flange hex nuts. Repeat for other side. Flange nuts will be secured after flag angle spacing is completed in step, Top Section.
Flag angle
1/4”-20 Flange hex nuts
Quick Install vertical track
Tools: None
Stud plate
Flag angle
1/4”-20 Flange hex nuts
Fully Adjustable vertical track
1/4”- 20 x 9/16” Track bolts
Quick Install Jamb Brackets
3
NOTE: If you have Fully Adjustable jamb brackets, skip this step. NOTE: If you have riveted track, skip this step.
Measure the length of the vertical tracks. Using the jamb bracket schedule, determine the placement of the jamb brackets for your door height and track length. To install the jamb brackets, align the Quick Install tab on the Quick Install jamb bracket with the Quick Install feature in the vertical track and turn the bracket perpendicular to the track so the mounting flange is toward the back (flat) leg of the track. Repeat for other side.
Tools: None
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
Bottom hole Middle hole Top hole
Jamb bracket
Q.I. tab
in place
Mounting flange
Q.I. jamb
bracket
(9800 Non-Sonoma) Jamb Bracket Schedule
DOOR HEIGHT
6’0”
6’6”
6’8”
6’10”
7’0”
7’3”
7’6”
7’9”
8’0” (4 Sec)
DOOR HEIGHT
6’6”
6’8”
6’10”
7’0”
7’4”
7’6”
7’8”
7’10”
8’0” (4 Sec)
TRACK
LENGTH
57.50”
(1461mm)
63.50”
(1613mm)
65.50”
(1664mm)
67.50”
(1715mm)
69.50”
(1765mm)
72.50”
(1842mm)
75.50”
(1918mm)
78.50”
(1994mm)
81.50”
(2070mm)
TRACK
LENGTH
63.50”
(1613mm)
65.50”
(1664mm)
67.50”
(1715mm)
69.50”
(1765mm)
73.50”
(1867mm)
75.50”
(1918mm)
77.50”
(1969mm)
79.50”
(2019mm)
81.50”
(2070mm)
1ST SET 2ND SET 3RD SET
JAMB BKT POSITION JAMB BKT POSITION JAMB BKT POSITION
5 M 8 B - -
3 B 6 M - -
3 B 6 M - -
3 B 6 M - -
3 B 6 M - -
3 B 7 T 8 T
3 B 7 T 8 T
3 B 7 T 8 T
3 B 7 T 8 T
B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE
(9800 Sonoma) Jamb Bracket Schedule
1ST SET 2ND SET 3RD SET
JAMB BKT POSITION JAMB BKT POSITION JAMB BKT POSITION
3 B 6 M - -
3 B 6 M - -
3 B 6 M - -
3 B 6 M - -
3 B 7 T 8 T
3 B 7 T 8 T
3 B 7 T 8 T
3 B 7 T 8 T
3 B 7 T 8 T
B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE
Fully Adjustable Jamb Brackets
4
NOTE: If you have Quick Install jamb brackets, skip this step. NOTE: If you have riveted track, skip this step. NOTE: The bottom jamb bracket is always the shortest bracket, while the center jamb
bracket is the next tallest. If three jamb brackets per side are included with your door, you will have received a top jamb bracket, which is the tallest.
To attach the bottom jamb bracket, locate lower hole of the hole/ slot pattern of the 1st hole set on the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/ slot
6
Tools: None
Page 7
pattern. Secure jamb bracket using (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”-20 flange hex nut. Repeat for other side.
Place the center jamb bracket over the lower hole of the hole/ slot pattern that is centered between the bottom jamb bracket and flag angle of the 2nd hole set. Secure jamb bracket using (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”-20 flange hex nut. Repeat for other side.
If a top jamb bracket was included, secure it to vertical track using the lower hole of the hole/ slot pattern in the 3rd hole set and (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”-20 flange hex nut. Repeat for other side.
1st hole set
Lower hole of hole/ slot pattern
Vertical track
2nd hole set 3rd hole set
1/4”- 20 Flange hex nut
1/4”- 20 x 9/16”
F.A. jamb
bracket
Track bolt
Top of track
Jamb bracket in place
Bottom Corner Brackets
5
NOTE: The bottom section can be identified by the smallest graduated edge hinge of the
factory installed graduated edge hinges, see Parts Breakdown on page 2 Locate the left hand bottom corner bracket. Align the bottom corner bracket horizontally with
the top edge of the factory attached bottom corner bracket. Also align the bottom corner bracket vertically with the left edge of the bottom section. Attach the bottom corner 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.
Tools: Power drill, 7/16” Socket driver
Single graduated end hinge (Hinge tube)
Short stem track roller
End cap
Left hand bottom corner bracket
Counterbalance
lift cable
3/8” Washer
Clevis pin
Cotter pin
Short stem track roller
Factory attached bottom corner bracket
Long stem track roller
Double graduated end hinge (Hinge tube)
Bottom section
Bottom weather seal
Cable
loop
Bottom corner bracket
Counterbalance
lift cable
Washer
Cotter pin
Bottom Section
6
Center the bottom section in the door opening. Level the section using wooden shims (if necessary) under the bottom section.
Tools: Level, Wooden shims (if necessary)
3/8”
Clevis
pin
WARNING WARNING
FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN, AL­LOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR FATAL INJURY.
Uncoil the counterbalance cables. Place clevis pin into the inside tab of the bottom corner bracket and slide the cable loop of the counterbalance lift 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 short stem track roller into the factory attached bottom corner brackets and another into the #1 graduated end hinges at the top of the bottom section. Repeat for other side.
NOTE: Larger doors will use long stem track rollers with double graduated end hinges. NOTE: Verify bottom weather seal is aligned with bottom section. If there is more than 1/2”
excess weather seal on either side, trim weather seal even with bottom section.
Left hand bottom corner bracket
(4) 1/4”-20 x 11/16” Self drilling screws
(1)1/4” - 20 x 5/8” Tamper resistant self drilling screw
Bottom weather seal
End cap
Bottom section
Factory attached bottom corner bracket
Weather seal
Level
Bottom section
Wooden shims
(If necessary)
Vertical Tracks
7
IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION
OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.
IMPORTANT: THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE. IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.
Position the left hand vertical track assembly over the track rollers of the bottom section. Drill 3/16” pilot holes into the door jamb for the lag screws.
Loosely fasten jamb brackets and flag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spac­ing, between the bottom section and vertical track. Repeat same process for other side.
Tools: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure, Level, Step ladder
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
7
Page 8
Flag angle
Vertical
track
assembly
Jamb bracket
Bottom section
5/16” x 1-5/8” Lag screws
Track rollers
Floor
12R FA
15R FA 15R QI12R QI
Flag angle lag screw locations
3/8” to 5/8”
Spacing
Bottom section
Vertical track
Track roller
Stacking Sections
8
NOTE: The sections can be identified by the graduation of the factory installed end hinges.
The smallest graduated end hinge on section should be stacked on top of the bottom section, with each graduated end hinge increasing as the sections are stacked, see Parts Breakdown on page 2.
NOTE: Make sure graduated end and center hinges are flipped down, when stacking another section on top.
NOTE: Larger doors will use long stem track rollers with double graduated end hinges. Place track rollers into graduated end hinges of remaining sections. With assistance, lift second section and guide the track rollers into the vertical tracks. Lower
section until it is seated against bottom section. 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 center hinge(s) first; then end hinges last using 1/4”-14 x 5/8” self tapping screws.
NOTE: To prevent center hinge leaf(s) from rotating, first secure the top middle hole of the center hinge leaf with one 1/4” – 14 x 5/8” self-tapping screw then secure the other two holes.
NOTE: Larger doors with double graduated end hinges, fasten both hinges to connect the sections using 1/4” - 14 x 5/8” self-tapping screws.
Repeat same process for other sections, except top section. IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE
SECURING WITH 1/4”-14 X 5/8” SELF TAPPING SCREWS. THERE SHOULD BE NO GAP BETWEEN THE HINGE LEAFS AND THE SECTIONS.
Tools: Power drill,7/16” Socket driver
Top Fixtures
9
Remove, but retain (2-4) 1/4”- 14 x 7/8” self drilling screws from the right side of the strut, allowing enough room to slide the top fixture between the section and the strut.
Slide the top fixture assembly between the strut and section. Align the edge of the top fixture parallel to the top section edge. Secure the top fixture and strut to the top section with (3) 1/4”- 20 x 7/8” self drilling screws through the upper and lower slots of the top fixture. Finish re-attaching the strut using the 1/4”- 20 x 7/8” self drilling screws removed previously. Insert track roller into top fixture. Repeat for left hand side.
Top
section
Tools: Power drill, 7/16” Socket driver
Strut
(3) 1/4”-20 x 7/8” Self drilling screws
End cap
Short stem track roller
Top fixture
base
Drawbar Operator Bracket
10
NOTE: If you’re installing a drawbar operator, the drawbar operator bracket must be mounted
and secured prior to installing top section. IMPORTANT: WHEN CONNECTING A DRAWBAR OPERATOR TYPE GARAGE DOOR OPENER
TO THIS DOOR, A WAYNE-DALTON OPERATOR/ DRAWBAR OPERATOR BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY STRUT PROVIDED WITH THE DOOR. THE INSTALLATION OF THE DRAWBAR OPERATOR MUST BE AC­CORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY.
Remove, but retain (4-6) 1/4”-20 x 7/8” self drilling screws from the center of the strut, allowing the drawbar operator bracket to slide between the section and the strut.
NOTE: For retro fit applications, the drawbar operator bracket must be aligned with an exist­ing drawbar operator.
Locate the center of the top section and slide drawbar operator bracket under strut till the drawbar operator bracket is seated against the strut flange.
NOTE: Prior to fastening drawbar operator bracket to top section, ensure the top edge of drawbar operator bracket is aligned with the top edge of the section, as shown.
Attach the drawbar operator bracket using (8) 1/4” – 20 x 11/16” self drilling screws (as shown). Finish re-attaching the strut using the self tapping screws removed previously.
Tools: Power drill, 7/16” Socket driver
Top section
Top section
Left double graduated
end hinge with long
stem track roller
Right double graduated
end hinge with long
stem track roller
Vertical tracks
1/4”-14 x 5/8” Self tapping screw locations
Left graduated end hinge with short stem track roller
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
Lock section
Alignment sticker
Center
hinge(s)
Alignment sticker
P/N # 327985 NEW 9-04-06P/N # 327985 NEW 9-04-06
Secure top middle hole first
Right graduated end hinge
with short stem track roller
Drawbar operator bracket
Strut
1/4” - 20 x 7/8” Self-drilling screws
Drawbar operator bracket in place under strut
Strut
(8) 1/4” - 20 x 11/16” Self-drilling screws
Top Section
11
Place the top section in the opening. Temporarily secure the top section by driving a nail into the header near the center of the door and bending it over the top section. Now, flip up the graduated end hinge and center hinge leaves, hold tight against section, and fasten center hinges first and end hinges last (refer to step, Stacking Sections). Vertical track alignment is critical. Position flag angle between 1-11/16” (43 mm) to 1-3/4” (44 mm) from the edge
8
Tools: Hammer, Power drill, 7/16” Socket driver, 7/16” Socket, 7/16” Wrench, Ratchet wrench, Step ladder, Tape measure
Page 9
of the door; tighten the bottom lag screw. Flag angles must be parallel to the door sections. Repeat same process for other side.
IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES MUST BE DOOR WIDTH 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 jamb bracket(s) and tightening the other lag screws. Repeat for other side.
FOR FULLY ADJUSTABLE TRACK:
Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Push the vertical track against the track rollers so that the track rollers are touching the deepest part of the curved side of the track; tighten all the track bolts and nuts. Repeat for other side.
Door width + 3-3/8” to 3-1/2”
Flag angle
Nail
Top section
1-11/16” to 1-3/4”
Flag angle
Top section
Vertical track against track rollers
Horizontal Tracks/Q.I Flag Angles
12
NOTE: If you have Quick Install flag angles, complete this step.
To install horizontal track, place the top rail end over the top track roller of the top section. Align key slot of the bottom rail end of horizontal track with the Quick Install tab of the flag angle. Push curved portion of horizontal track down to lock in place.
Tools: Ratchet wrench, 9/16” Socket, 9/16” Wrench, level, Step ladder
WARNING WARNING
DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR, AS OUTLINED IN STEP, REAR BACK HANGS, OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY.
Level the horizontal track assembly and bolt the top rail of the horizontal track to the encoun­tered slot in the flag angle using (1) 1/4”-20 x 9/16” track bolt, (1) 1/4”-20 flange hex nut and (1) 5/16 washer. Repeat for other side.
Remove the nail that was temporarily holding the top section in place, installed in step, Top Section.
IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION.
NOTE: If an idrive® opener will be installed, position horizontal tracks slightly above level.
Flagangle
Flag angle
Bottom rail of horizontal track
Quick Install tab
Vertical track
Quick Install tab in place
Tracks flush
Key slot
Vertical track
Horizontal Tracks/F.A. Flag Angles
13
NOTE: If you have Fully Adjustable flag angles, complete this step.
To install horizontal track, place the top rail end over the top track roller of the top section. Align the bottom rail end of the horizontal track with the top of the vertical track. If you have Quick Install horizontal track, tighten the bottom rail of the horizontal track to the flag angle with (1) stud plate and (2) 1/4”-20 flange hex nuts. If you have Universal horizontal track,
Tools: Ratchet wrench, 7/16” Socket, 9/16” Socket, 9/16” Wrench, level, Step ladder, Flat tip screwdriver
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
Washer
1/4”-20 Flange hex nut
1/4”-20 x 9/16” Track bolt
Top rail of horizontal track
tighten the bottom rail of the horizontal track to the flag angle with (2) 1/4”-20 x 9/16” track bolts and (2) 1/4”-20 flange hex nuts.
WARNING WARNING
DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR, AS OUTLINED IN STEP, REAR BACK HANGS, OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY.
Level the horizontal track assembly and bolt the top rail of the horizontal track to the encoun­tered slot in the flag angle using (1) 1/4”-20 x 9/16” track bolt, (1) 1/4”-20 flange hex nut and (1) 5/16 washer. Repeat for other side.
Remove the nail that was temporarily holding the top section in place, installed in step, Top Section.
IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION.
NOTE: If an idrive® opener will be installed, position horizontal tracks slightly above level.
Washer
1/4”-20 Flange hex nut
Left end bearing bracket
1/4”-20 x 9/16” Track bolt
Top rail of horizontal track
(3) 5/16” x 1-5/8” Lag screws
Bottom rail Quick Install Horizontal track
1/4”-20 Flange hex nuts
Flag angle upper slot
Vertical track
Stud plate
Bottom rail Fully Adjustable Horizontal track
1/4”-20 Flange hex nuts
Flag angle upper slot
Vertical track
1/4”-20 x 9/16” Track bolts
Flagangle
End Bearing Brackets
14
NOTE: Right and left hand is always determined from inside the garage looking out.
End bearing brackets are right and left hand. Align the bottom edge of left end bearing bracket with the top edge of the flag angle. Maintaining this alignment, also align the right edge of the end bearing bracket with the right edge of the flag angle.
Secure the end bearing bracket to the jamb using (3) 5/16” x 1-5/8” lag screws, as shown. Repeat same process for the other side.
Top edge of flag angle
Tools: Step ladder, Power drill, 7/16” Socket driver
Left end bearing bracket
Bottom edge
Top section
Center Bracket Bushing Assembly
15
Locate the center of the door. Mark a vertical pencil line on the mounting surface above the door, at the center. Measure from the center of the bearing, in one of the end bearing brackets, downwards, to the top the door. Using that measurement, measure that distance upwards from the top of the door to the mounting surface and mark a horizontal pencil line which intersects the vertical pencil line. Align the edge of the center bracket with the vertical pencil line and the center of the center bracket with the horizontal pencil line; this is to ensure the torsion shaft is level between the center and end bearing brackets.
Attach the center bracket 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 A 5/16” X 1-5/8” TAMPER-RESISTANT LAG SCREW INSTEAD OF THE 5/16” X 2” TAMPER-RESISTANT LAG SCREW IF MOUNTING SURFACE IS MOUNTED OVER MASONRY. TAMPER-RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BEARING BRACKET.
9
Tools: Step ladder, Power drill, 7/16” Socket driver, 1/4” Torx bit, Level, Tape measure, Pencil
Top section
Page 10
Center of end bearing bracket
Mounting surface
Vertical line
Horizontal line
Equal distance (top of door section to horizontal line)
Center bracket
Red cable drum
(left hand side)
Black cable drum
(right hand side)
Torsion shaft
Left hand wound, black winding cone (left hand side)
Center bracket
bushing
Right hand wound,
red winding cone
(right hand side)
Mounting surface
Vertical line
(2) 5/16” x 1-5/8”
Lag screws
Horizontal line
Center bracket
(1) 5/16” X 2” or (1) 5/16” x 1-5/8” Tamper-resistant lag screw
Torsion Spring Assembly
16
IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING
LOOKING OUT. NOTE: Identify the torsion 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.
Facing the inside of the door, lay the torsion shaft on the floor. Lay the torsion spring with the black winding cone and the red cable drum at the left end of the torsion shaft. Lay the torsion spring with the red winding cone and the black cable drum at the right end of the torsion shaft.
NOTE: The set screws used on all torsion winding cones and cable drums are now colored red. DO NOT identify right and left hand by the set screw color.
Slide the center bracket bushing onto the torsion shaft followed by the torsion springs and cable drums.
IMPORTANT: THE CENTER BRACKET BUSHING, TORSION SPRINGS, AND CABLE DRUMS MUST BE POSITIONED, AS SHOWN.
With assistance, pick up the torsion spring assembly and slide one end of the torsion shaft through one end bearing bracket. Lay the middle of the torsion shaft into the center bracket. Slide the other end of the torsion shaft into the other end bearing bracket. Position the torsion shaft so that equal amounts of the shaft extend from each end bearing brackets.
Tools: Step Ladder
Left hand end bearing bracket
Torsion shaft
bushing assembly
Torsion shaft
Equal spacing
Center bracket
Center bracket bushing
Center bracket
Torsion spring(s)
Right hand end bearing bracket
Black cable drumRed cable drum
Torsion Spring Attachment
17
Slide the center bracket bushing into the center bracket. Align the stationary spring cone(s) with the holes in the center bracket bushing assembly. Secure the torsion spring(s) to the center bracket bushing assembly with (2) 3/8”-16 x 1-1/2” hex head bolts and (2) 3/8”-16 nuts.
IMPORTANT: THE SPRING WARNING TAG(S) SUPPLIED MUST BE SECURELY ATTACHED TO THE STATIONARY SPRING CONE(S) IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING WARNING TAG BE REQUIRED, CONTACT WAYNE-DALTON FOR FREE REPLACEMENTS.
Stationary spring cone
Tools: Step Ladder, 1/2” Wrench
Center bracket
Torsion spring
Center bracket bushing
Stationary spring cone
Spring warning tags
Torsion spring
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10
Page 11
Torsion spring
(2) 3/8”-16 Nuts
Center bracket bushing assembly
Torsion spring
Vice clamps above third
track roller on both sides of
door
Stationary spring cone
(2) 3/8”-16 x 1-1/2” Hex head bolts
Counterbalance Lift Cables
18
Starting on the left hand side, thread the counterbalance lift cable up and around the front side of the left hand cable drum.
IMPORTANT: VERIFY THAT THERE ARE NO COUNTERBALANCE LIFT CABLE OBSTRUCTIONS. Hook the counterbalance lift cable into the left hand cable drum. Slide the left hand cable
drum onto the torsion shaft and up against the left hand end bearing bracket. Counterbal­ance lift cable should terminate at the 9 o’clock position. Tighten the (2) set screws in the cable drum to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten set screws one full turn). Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach locking pliers to the torsion shaft and brace locking pliers up against the jamb to keep counterbalance lift cable taut.
Repeat for right hand side. IMPORTANT: INSPECT EACH COUNTERBALANCE LIFT CABLES MAKING SURE THEY ARE
SEATED PROPERLY ONTO THE CABLE DRUMS AND THAT BOTH COUNTERBALANCE LIFT CABLES HAVE EQUAL TENSION.
Counterbalance lift
cable installed
Tools: Step Ladder, Locking Pliers, 3/8” Wrench
Left hand
end bearing
bracket
Torsion
shaft
Locking
pliers
Left hand
cable drum
Jamb
Counterbalance lift cable
Cable drum set screws
Securing Door For Spring Winding(s)
19
With the door in the fully closed position, place vice clamps onto both vertical tracks just above the third track roller. This is to prevent the garage door from rising while winding springs.
Tools: Vice Clamps
WARNING WARNING
FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.
Bottom section
Vice clamps attached to inner
and outer rail of vertical track
Winding Springs
20
Position a ladder slightly to the side of the spring so that the winding cone is easily acces­sible, and so your body is not directly in 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.
Tools: Step Ladder, Approved winding bars, 3/8” Wrench
Door Height Approximate Spring Turns
6’0” 6-7/8 Turns
6’3” 7-1/8 Turns
6’5” 7-1/4
6’6” 7-3/8 Turns
6’8” 7-1/2
6’9” 7-5/8 Turns
7’0” 7-7/8 Turns
7’3” 8 Turns
7’6” 8-1/4 Turns
7’9” 8-1/2 Turns
8’0” 8-3/4 Turns
WARNING 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 rods into the holes of the springs winding cone, rotate the winding cone downward toward the floor, 1/4 turn at a time, until the required number of complete turns for your door height is achieved. As the last 1/8 to 1/4 turn is achieved, securely hold the winding rod while tightening both set screws in the winding cone to 14-15 ft. lbs. of torque (once set screws contact the torsion shaft, tighten screws one full turn).
Carefully remove winding rod from winding cone. Repeat for the opposite spring. While holding the door down to prevent it from raising unexpectedly in the event the spring(s) were over-wound, carefully remove the locking pliers from the torsion shaft and vertical tracks.
Adjustments to the number of turns stated may be necessary. If door rises off floor under spring tension alone, reduce spring tension until door rests on the floor. If the door is hard to rise or drifts down on its own, add spring tension.
NOTE: An unbalanced door such as this can cause garage door opener operation problems.
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
11
Page 12
Spring
Set screws
Approved
Torsion shaft
Winding cone
winding rods
Rear Back Hangs
21
IMPORTANT: HOLD THE DOOR DOWN TO PREVENT IT FROM RISING UNEXPECTEDLY IN THE
EVENT THE SPRING(S) WAS OVER-WOUND AND CAUTIOUSLY REMOVE VICE CLAMPS FROM VERTICAL TRACKS.
Raise the door until the top section and half of the next section are in the horizontal track radius. Do not raise door any further since rear of horizontal tracks are not yet supported.
Tools: Ratchet wrench, 1/2” Socket, 1/2” Wrench, (2) Vice clamps, Tape measure, Level, Hammer, Step Ladder
WARNING WARNING
RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE OR FATAL INJURY.
Clamp a pair of vice clamps onto the vertical tracks just above the second track roller on one side, and just below the second track roller on the other side. This will prevent the door from raising or lowering while installing the rear back hangs.
Using perforated angle (may not be supplied), (2) 5/16” x 1-5/8” hex head lag screws and (3) 5/16” bolts with nuts (may not be supplied), fabricate rear back hangs for the horizontal tracks. Attach the horizontal tracks to the rear back hangs with 5/16”-18 x 1 hex bolts and nuts (may not be supplied). Horizontal tracks must be level and parallel with door within 3/4” to 7/8” maximum of door edge.
NOTE: If an idrive® opener is installed, position horizontal tracks one hole above level when securing it to the rear back hangs.
If door still does not balance correctly, contact a qualified door agency. If the door still does not operate easily, lower the door into the closed position, UNWIND THE SPRING(S) FULLY (Reference the insert “Removing The Old Door/Preparing The Opening” section on torsion spring removal), and recheck the following the items:
1.) Check the door for level.
2.) Check the torsion shaft for level.
3.) Check the track spacing.
4.) Check the counterbalance lift cables for equal tension.
5.) Check the track for potential obstruction of the track rollers.
6.) Clamp locking pliers onto track and rewind springs. IMPORTANT: If door still does not operate properly, then contact a trained door system
technician.
Horizontal tracks
Vice clamp
Vice clamp
2nd Track roller
WARNING WARNING
KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4” TO 7/8” MAXI­MUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN SEVERE OR FATAL INJURY.
IMPORTANT: DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR
BACK HANGS THAT CANTILEVERS 4” OR MORE BEYOND A SOUND FRAMING MEMBER. NOTE: If rear back hangs are to be installed over drywall, use (2) 5/16” x 2” hex head lag
screws and make sure lag screws engage into solid structural lumber.
NOTE: 26” angle must be attached to sound framing members and nails should not be used.
Now, permanently attach the weatherstrips on both door jambs and header. The weather­strips were temporarily attached in Preparing the Opening, in the pre-installation section of this manual.
NOTE: When permanently attaching the weatherstrips to the jambs, avoid pushing the weath­erstrips too tightly against the face of door.
WARNING 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.
Now, lift door and check its balance. Adjustments to the required number of spring turns stated may be necessary. If door rises 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. A poorly balanced door can cause garage door operator operation problems.
To adjust spring tension, fully close door. Apply vice grips to track above third track roller. Insert a winding rod into the winding cone. On single spring doors, counterbalance lift cable tension must be maintained by placing vice grips on torsion shaft before loosening set screws in the winding cone. Push downward on the winding rod while carefully loosening the set screws in the winding cone. BE PREPARED TO SUPPORT THE FULL FORCE OF THE TORSION SPRING ONCE THE SET SCREWS ARE LOOSE. Carefully adjust spring tension 1/4 turn. Retighten both set screws in the winding cone and repeat for the other side. Recheck door balance DO NOT ADJUST MORE THAN 1/2 TURN FROM THE RECOMMENDED NUMBER OF TURNS.
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer,
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12
Horizontal
track
Hex bolts must extend into the
track to serve as a roller stop
5/16”-18 x 1-1/4”
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
(3) 5/16” Bolts and nuts
Perforated angle
Page 13
(3) 5/16”
Bolts and nuts
Sound framing members
Horizontal
track
Perforated angle
Hex bolts must extend into the
5/16”-18 x 1-1/4”
track to serve as a roller stop
3/4” To 7/8”
Door edges
Horizontal tracks
Perforated angle bolted using (2) 5/16” x 1-5/8” hex head lag screws to ceiling member and parallel to door
3/4” To 7/8”
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
13
Page 14
Optional Installation
Door Arm Hookup
Tools: Needle nose pliers
Align hole in the door arm with holes in drawbar operator bracket tabs, as shown. Insert 5/16” x 1-1/4” clevis pin, making sure hole in clevis pin is outside of second tab of drawbar operator bracket. Insert hairpin cotter into clevis pin hole and spread hairpin cotter to secure assembly, as shown.
Drawbar operator bracket tabs
Cotter pin
Door arm
Clevis pin
5/16”x 1-1/4” Clevis pin
Drawbar operator bracket
Spread cotter pin
Inside Lock
Tools: Power drill, 7/16” Socket driver, Tape measure
Install the inside lock on the second section of the door. Secure the lock to the section with (4) 1/4”-20 x 11/16” self drilling screws. Square the lock assembly with the door section, and align with the square hole in the vertical track. The inside lock should be spaced approximately 1/8” away from the section edge.
IMPORTANT: INSIDE LOCK(S) MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR.
Second section 1/8”
Inside lock
End cap
Square hole in vertical track
(4) 1/4”-20 x 11/16” Self drilling screws
Pull Down Rope
Tools: Power drill, 1/8” Drill bit, Tape measure
WARNING WARNING
DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH OPERATORS. CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY.
Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the right or left side of jamb. Drill 1/8” pilot hole for no. 6 screw eye. Tie the pull down rope to the no. 6 screw eye and to the bottom corner bracket, as shown.
No. 6 Screw eye
48” to 50” From floor
Pull down rope
Pull down rope
Bottom corner bracket
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
14
Page 15
Maintenance
Cleaning Your Garage Door
IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR! While factory-applied finishes on garage doors are durable, it is desirable to clean them on a
routine basis. Some discoloration of the finish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of direct exposure to sunlight.
Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, a periodic washing of the garage door is recommended.
THE FOLLOWING CLEANING SOLUTION IS RECOMMENDED:
A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dis­solved into five gallons of warm water will aid in the removal of most dirt.
NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.
NOTE: Be sure to clean behind weatherstrips on both sides and top of door. CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH. GLASS CLEANING INSTRUCTIONS
Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.
ACRYLIC CLEANING INSTRUCTIONS
Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on particles. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic glazing. Dry glazing with a clean damp chamois.
NOTE: Do not use any window cleaning fluids, scouring compounds, gritty cloths or solvent­based cleaners of any kind.
Painting Your Garage Door
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.
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:
1. Re-painting of finish painted steel doors cannot be warranted, as this condition is totally beyond the door manufacturer’s control.
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
Finishing
NOTE: Prior to finishing and/or refinishing your door, refer to the procedures outlined in the DASMA Technical Data Sheets # 179 and #162 at www.dasma.com.
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)
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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 top coat (A high-quality clear polyurethane) following the manufacturer instructions.
FINISHING:
It is recommended that the door be purchased pre-finished due to the size of the door, required spray equipment and 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.
Operation and Maintenance
OPERATING YOUR GARAGE DOOR:
Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. When correctly installed, your Wayne-Dalton door will operate smoothly. Always operate your door with controlled movements. Do not slam your door or throw your door into the open position, this may cause damage to the door or its components. If your door has an electric opener, refer to the owner’s manual to disconnect the opener before performing manual door operation below.
Manual door operation:
For additional information on manual garage door operations go to www.dasma.com and reference TDS 165.
IMPORTANT: DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN OPENING AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES / SUITABLE GRIPPING POINTS WHEN OPERATING THE DOOR MANUALLY.
Opening a Door: Make sure the lock(s) are in the unlocked position. Lift the door by using the lift handles / suitable gripping points only. Door should open with little resistance.
Closing a Door: From inside the garage, pull door downward using lift handles / gripping point only or a high friction area only. If you are unable to reach the lift handles/ suitable gripping points only, use pull down rope affixed to the side of door. Door should close completely with little resistance.
Using an electric operator: IMPORTANT: PULL DOWN ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR
MADE INOPERATIVE IN THE UNLOCKED POSITION. When connecting a drawbar (trolley type) garage door operator to this door, an drawbar opera-
tor and or drawbar operator bracket must be securely attached to the top section of the door, along with any struts provided with the door. Always use the drawbar operator and or drawbar operator bracket supplied with the door. To avoid possible damage to your door, Wayne-Dalton recommends reinforcing the top section on models 8000, 8100, 8200 and 9100 doors with a strut (may or may not be supplied). The installation of the drawbar operator must be according to manufacturer’s instructions and force settings must be adjusted properly. Refer to the owner’s manual supplied with your drawbar operator for complete details on installation, operation, maintenance and testing of the operator.
MAINTAINING YOUR GARAGE DOOR:
Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. Perform routine maintenance steps once a month, and have the door professionally inspected once a year. Review your Installation Instructions and Owner’s Manual for the garage door. These instructions are available at no charge from Wayne-Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at www.wayne-dalton. com. For additional information on garage door/operator maintenance go to www.dasma.com and reference TDS 151, 167 and 179.
Monthly Inspections:
1. Visual Inspection: Closely inspect jambs, header and mounting surface. Any wood found not
to be structurally sound must be replaced. Inspect the springs, counterbalance lift cables, track rollers, pulleys, rear back hangs and other door hardware for signs of worn or broken parts. Tighten any loose screws and/or bolts. Check exterior surface of the door sections for any minor cracks. Verify door has not shifted right or left in the opening. If you suspect problems, have a trained door system technician make the repairs.
WARNING WARNING
GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACKETS, AND OTHER HARDWARE ATTACHED TO THE SPRINGS ARE UNDER EXTREME TEN­SION, AND IF HANDLED IMPROPERLY, CAN CAUSE SEVERE OR FATAL INJURY. ONLY A TRAINED DOOR SYSTEMS TECHNICIAN SHOULD ADJUST THEM, BY CAREFULLY FOLLOWING THE MANUFACTURER’S INSTRUCTIONS.
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WARNING WARNING
NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR LAG SCREWS ON THE COUNTERBALANCE (END OR CENTER BEARING BRACKETS) SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR. THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY, HAVE ANY SUCH WORK PER­FORMED BY A TRAINED DOOR SYSTEMS TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.
TorqueMaster® Plus Springs: Pawl knob(s) (located on the TorqueMaster® end brackets above the door) should be engaged to prevent the door from rapidly descending in case of spring failure or forceful manual operation.
Torsion Springs: The torsion springs (located above the door) should only be adjusted by a trained door systems technician. DO NOT attempt to repair or adjust torsion springs yourself.
Extension Springs: A restraining cable or other device should be installed on the extension spring (located above the horizontal tracks) to help contain the spring if it breaks.
2. Door Balance: Periodically test the balance of your door. If you have a garage door drawbar operator, use the release mechanism so you can operate the door by hand when doing this test. Start with the door in the fully closed position. Lift the door to check its balance. Adjust TorqueMaster® or Extension spring(s), if door lifts by itself (hard to pull down) or if door is difficult to lift (easy to pull down). DO NOT attempt to repair or adjust Torsion Springs yourself. To adjust TorqueMaster® or Extension spring(s), refer to your installation instructions and owner’s manual. If in question about any of the procedures, do not perform the work. Instead, have it adjusted by a trained door systems technician.
3. Lubrication: The door should open and close smoothly. Ensure the door track rollers are rotating freely when opening and closing the door. If track rollers do not rotate freely, clean the door tracks, removing dirt and any foreign substances. Clean and lubricate (use a non-silicon based lubricant) graduated end hinges, steel track rollers and bearings. DO NOT lubricate plastic idler bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difficult use a graphite dust to lubricate.
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
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Warranty
Lifetime limited warranty
Model 9800
Subject to the terms and conditions contained in this Lifetime Limited Warranty, Wayne-Dalton (“Manufacturer”) warrants the sections of the garage door for as
long as you own the door against:
i) 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.
ii) The door hardware (except counterbalance 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 the terms and conditions below.
The exceptions to the Limited Lifetime portion of the warranty are the following, which will be warranted for a period of three (3) years from the date of installa-
tion against:
iii) 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.
iv) Peeling, cracking, chalking or fading of the factory-applied coating from the time of installation. If the door is re-stained or re-painted, other than the clear
coat recommendations in our instructions, the warranty for the factory-applied coating is void.
The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this warranty against defects in material and work-
manship 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 Manufac-
turer’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. Un-
less 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 War-
ranty; provided 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 Manufac-
turer, 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.
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
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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.
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
Thank you for your purchase.
AFTER INSTALLATION IS COMPLETE, FASTEN THIS MANUAL NEAR THE GARAGE DOOR.
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