Wayne-Dalton 9800 User Manual

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 owner’s 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

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):

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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

2

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)

3

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

4

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

5

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