Wayne-Dalton TORSION SPRING 9800 User's Manual
Contents
1. up Socket PARALLEL AND WITHIN 3 4 MAXIMUM OF DOOR EDGE uo Wrench OTHERWISE DOOR COULD FALL RESULTING IN SEVERE INJURY OR 2 Vice Clamps DEATH Raise the door until the top section and half of the next section are in a horizontal position Do not raise door any further since rear of horizontal track is not yet supported A WARNING RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE INJURY OR DEATH INSTALLATION Clamp a pair of vice clamps on the vertical tracks just above the second roller on one side just below the second roller on the other side This will prevent the door from raising or lowering while installing the rear support VERTICAL TRACK Using perforated angle 5 16 x 1 5 8 hex head lag screws and 5 16 bolts with nuts may not be supplied fabricate rear support for horizontal tracks Attach horizontal tracks to the rear supports with 5 16 18 x 1 1 4 hex bolts and nuts may not be supplied Horizontal tracks must be level and parallel with door NOTE If rear supports are to be installed over drywall use 5 16 x 2 hex head lag screws A2. OPERATOR BRACKET IN PLACE UNDER U BAR 6 1 4 20 X 7 8 SELF DRILLING SCREWS Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 17 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com INSTALLATION 9 Top Section Tools Needed Place the top section in the opening DOOR WIDTH and vertically align with lower sections 43 3 8 TO 3 1 2 Hammer Tape Measure Temporarily secure the top section by driving a nail in the header near the Power Drill center of the door and bending it over the top section 7 16 Socket Driver Now flip up hinge leaf against section fastening center hinges first and end hinges last Refer to Step 6 When installing a door with a torsion counterbalance system vertical track alignment is critical Position flagangle between 1 11 16 43 mm to 1 3 4 44 mm from the edge of the door Tighten the bottom lag screw Flagangles must be parallel to the door sections Repeat for opposite side IMPORTANT THE DIMENSION BETWEEN THE FLAGANGLES MUST BE DOOR WIDTH PLUS 3 3 8 86MM TO 3 1 2 89 MM FOR SMOOTH SAFE VERTICAL TRACK DOOR OPERATION A Complete the vertical track installation ZA by securing the center jamb bracket s Y L
3. BOTTOM SECTION 14 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed Power Drill 7 16 Socket Driver Stacking Sections NOTE For door section identification see page 4 NOTE Make sure hinge leafs are flipped down when stacking another section on top Place rollers in hinge tubes of the second section lock section With assistance lift the second section and guide rollers into the vertical tracks Keep sections vertically aligned and fasten hinges to connect the sections using 1 4 14 x 5 8 self tapping screws Repeat for other section s except top section IMPORTANT END HINGES HAVE 2 SCREWS AND INTERMEDIATE HINGES HAVE 3 SCREWS NOTE Install lock at this time sold separately See instructions in OPTIONAL SIDELOCK INSTALLATION on page 27 3 1 4 14 X 5 8 SELF TAPPING SCREWS mE INTERMEDIATE HINGES Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 15 Y
4. T O O O O p PERFORATED ANGLE f 28 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com While factory applied finishes on steel 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 an annual washing of the door is recommended A mild solution of detergent and water will aid in the removal of most dirt The following solution mixture is recommended One cup of Tide or other common detergents which contain less than 0 5 phosphate dissolved into five gallons of warm water CAUTION NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH 1 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
5. 4 1 4 20 X 11 16 SELF DRILLING SCREWS PULL ROPE OPTIONAL INSTALLATION as Tools Needed Trolley Operator A WARNING OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR FAILURE TO ADJUST OPERATOR IF NECESSARY CAN RESULT IN SEVERE OR FATAL INJURY IF YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED FAILURE TO MAKE ADJUSTMENTS IF NECESSARY CAN RESULT IN SEVERE OR FATAL INJURY 1 Install operator rail 1 2 to 1 1 2 13 38 mm above high arc of top section of the door Mount operator to ceiling so that 1 to 1 1 2 25 38 mm clearance is maintained between trolley rail and top section when door is fully open trolley rail will slope down towards rear Attach door arm to operator bracket installed in Step 8 Attach operator rail to suitable mounting surface 2 x 6 lumber minimum Attach operator to ceiling using perforated angle IMPORTANT ANGLES MUST BE SECURELY ATTACHED TO SOUND FRAMING MEMBER S SUITABLE MOUNTING SURFACE 2 X 6 LUMBER MINIMUM NI Z D SE A
6. COUNTER GEAR COUNTER Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 7 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com PRE INSTALLATION TorqueMaster Spring Removal continued Tools Needed If the counterbalance cable is still taut and the TorqueMaster Spring Tube is difficult to rotate that is an indication that spring Recommended tension still exists on the left hand spring tools from Repeat Steps 1 and 2 for releasing spring page 5 tension on the left hand side Step 4 Using a flat tip screwdriver pry the counter gear and counter cover REMOVE TOP from the right hand end bracket Fig 4 LAG SCREW on previous page Discard the counter gear and counter cover On double spring applications repeat for left hand side Step 5 Remove the upper 5 16 x USE LOCKING PLIERS 1 5 8 lag screw from the right hand end TO HOLD END BRACKET bracket Fig 5 Attach locking pliers to the upper portion of the end bracket and hold the housing steady while removing REMOVE 10 the lower 5 16 x 1 5 8 lag screw and A PHILLIPS HEAD 10 x 1 2 phillips head screw from the TESS SCREW end bracket Fig 6 Step 6 Holding the right hand end bracket steady with locking pliers carefully pry the end bracket and drive gear off the winding shaft using a f
7. ASTRAGAL DOOR OPENING BOTTOM SECTION A WOODEN SHIMS IF NECESSARY TUBE BOTTOM SECTION Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 13 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com INSTALLATION Tools Needed 3 16 Drill Bit Power Drill 7 16 Socket Driver Tape Measure Level 2 Vice Grips Vertical Track IMPORTANT THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT THE VERTICAL TRACK ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM Position the left hand vertical track assembly over the rollers of the bottom section Make sure the counterbalance cable is located between the rollers and the door jamb Drill 3 16 pilot holes for the lag screws Loosely fasten jamb brackets and flagangle to the jamb using 5 16 x 2 lag screws Tighten lag screw securing bottom jamb bracket to jamb to maintain 5 8 spacing Repeat for the right hand side LAG SCREW LOCATIONS VERTICAL TRACK l 5 8 ROLLER FLAGANGLE 5 16 X 2 s LAG SCREWS wi VERTICAL TRACK ASSEMBLY BOTTOM SECTION
8. red colored fasteners cables or supports To avoid possible severe or fatal injury have any such work performed by a trained door systems technician using proper tools and instructions 12 On electrically operated doors pull down ropes must be removed and locks must be removed or made inoperative in the open unlocked position 13 Top section of door may need to be reinforced when attaching an electric opener Check door and or opener manufacturer s instructions 14 VISUALLY inspect door and hardware monthly for worn and or broken parts Check to ensure door operates freely 15 Test electric opener s safety features monthly following opener manufacturer s instructions 16 NEVER hang tools bicycles hoses clothing or anything else from horizontal tracks Track systems are not intended or designed to support extra weight After installation is complete fasten this manual near garage door NOTE DEPENDING ON THE DOOR MODEL SOME PARTS LISTED Package Contents WILL NOT BE SUPPLIED IF NOT NECESSARY REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR DOOR SECTIONS AS REQUIRED 1 TORSION TUBE 2 FULLY ADJUSTABLE ooon RH LH FLAGANGLES 2 HORIZONTAL TRACKS WITH ATTACHED HORIZONTAL ANGLE RH LH AAW e Vu c A DOOR STOP amp NAILS WEATHER SEAL amp NAILS 1 CENTER BRACKET RIGHT AND LEFT IF INCLUDED IF INCLUDED COUNTERBALANCE CABLES
9. 0 o ao RH LH TORSION MANUAL RIGHT amp LEFT RIGHT amp LEFT 1 CENTER BRACKET 2 VERTICAL SPRINGS AS REQUIRED DRUMS END BEARING BRACKETS BUSHING RH LH TRACKS ROLLERS 1 OPERATOR BRACKET 2 TOP BRACKET 2 TOP BRACKET JAMB BRACKETS SCREW EYE amp PULL AS REQUIRED SLIDES BASES AS REQUIRED ROPE IF INCLUDED fm mm sm is 1 4 20 FLANGE HEX 2 3 8 16 1 4 14 X 5 8 SELF TAPPING 1 4 20 X 5 8 CARRIAGE 2 3 8 16 X 3 4 1 4 20 X 7 8 SELF DRILLING NUTS AS REQUIRED TEX NUTS SCREWS AS REQUIRED BOLTS AS REQUIRED HEX HEAD BOLTS SCREWS AS REQUIRED 2 3 8 16 X 1 1 2 HEX HEAD BOLT 5 16 X 2 TAMPER RESISTANT LAG 5 16 X 2 HEX HEAD LAG SCREWS AS REQUIRED SCREW AS REQUIRED Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 3 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed Door Section Identification NOTE This provides an alternative method for identifying your door sections stacking position Hinges are always pre attached at the top of each section except top section and the hinges are stamped for identification 1 2 3 and 4 4 only on five section doors See view below The stamp identifies the stacking sequence of the section The sequen
10. 1 2 MOTOR 64 mm of additional headroom is required BACKROOM REQUIREMENT Backroom is defined as the distance 99 14 Radius 90 125 needed from the opening back into the garage to allow the door 14 Radius 96 125 to open fully 80 14 Radius 10 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Installation IMPORTANT READ INSTRUCTIONS TITLED P4 REMOVING THE OLD DOOR ON PAGE 9 AND P5 PREPARING THE OPENING ON PAGE 10 BEFORE ATTEMPTING DOOR INSTALLATION IMPORTANT STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS END BRACKETS JAMB BRACKETS OPERATOR MOUNTING SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER PRESERVATIVE TREATED STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UNTREATED LUMBER NOTE It is recommended that 5 16 x 2 lag screws be pilot drilled using a 3 16 drill bit and 1 4 x 2 lag screws and 1 4 x 1 1 2 lag screws be pilot drilled using a 1 8 drill bit prior to fastening Attaching Fully Adjustable Flagangle to Vertical Track FULLY Tools Needed i ADJUSTABLE Hand tighten the flagangle to the rd FLAGANGLE vertical track using 2 1 4 20 x 5 8 c
11. ANY OF THE PROCEDURES DO NOT PERFORM THE WORK INSTEAD HAVE A QUALIFIED DOOR AGENCY DO THE INSTALLATION OR REPAIRS READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS Wear protective gloves during installation to avoid possible cuts from sharp metal edges 3 tis always recommended to wear eye protection when using tools otherwise eye injury could result 4 Avoid installing your new door on windy days Door could fall during the installation causing severe or fatal injury 5 Doors 12 0 wide and wider should be installed by two persons to avoid possible injury 6 Operate door ONLY when it is properly adjusted and free from obstructions 7 fadoor becomes hard to operate inoperative or is damaged immediately have necessary adjustments and or repairs made by a trained door system technician using proper tools and instructions 8 DO NOT stand or walk under a moving door or permit anybody to stand or walk under an electrically operated door 9 DO NOT place fingers or hands into open section joints when closing a door Use lift handles gripping points when operating door manually 10 DO NOT permit children to operate garage door or door controls Severe or fatal injury could result should the child become entrapped between the door and the floor 11 Due to constant extreme spring tension DO NOT attempt any adjustment repair or alteration to any part of the door especially to springs spring brackets bottom corner brackets
12. STRUCTURALLY SOUND f DOBR HEIGHT FRAMING COULD CAUSE SPRINGS TO VIOLENTLY ZO PULL MOUNTING PAD FROM WALL RESULTING IN SEVERE OR FATAL INJURY If you just removed your existing door or you are installing a new door complete all steps in PREPARING THE OPENING Recommended tools from page 5 For detailed technical information regarding the opening preparation refer to the DASMA Technical Data Sheet TDS 161 Connecting Garage Door Jambs to Building Framing at www dasma com The inside of your garage door opening should be framed with wood jambs and header It is recommended that 2 x 6 lumber be used The jambs must be plumb and the header level The jambs should extend a minimum of 14 356 mm above the top of the opening for Torsion springs applications For low headroom p applications the jambs should extend to the ceiling height A A BACKROOM Minimum side clearance required from the opening to the wall is A 3 1 2 89 mm IMPORTANT CLOSELY INSPECT JAMBS HEADER AND MOUNTING SURFACE ANY WOOD FOUND NOT TO BE SOUND MUST BE REPLACED The jambs and header must be securely fastened to sound framing members Do not place jambs and header over drywall paneling etc Heads of fasteners must be flush or below jamb and header WEATHER SEAL surface so they do not interfere with installation or operation of new door Torsion springs applications a suitable mounting surface must be firmly att
13. You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com zs Tools Needed Power Drill 7 16 Socket Driver Tools Needed Power Drill 1 8 Drill Bit Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Side Lock Install the side lock on the second section of the door Secure the lock to the section with 4 1 4 20 x 11 16 self drilling screws Square the lock assembly with the door section and align with the square hole in the vertical track The side lock should be spaced in approximately 1 8 from the section edge IMPORTANT SIDE LOCKS MUST BE REMOVED OR MADE INOPERATIVE IN THE UNLOCKED POSITION IF AN OPERATOR IS INSTALLED ON THE DOOR NOTE After completing this step continue with step 7 on page 16 Pull Rope A WARNING DO NOT INSTALL PULL ROPES ON DOORS WITH ELECTRIC OPERATORS CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY Measure and mark the jamb approximately 48 to 50 1220 to 1270 mm from floor on the right or left side of door Drill 1 8 pilot hole for No 6 screw eye Install the No 6 screw eye Tie the pull rope to the No 6 screw eye and to the bottom bracket as shown
14. a qualified and experienced door technician Instead have a professional door agency release the tension Step 1 Close the door and place vice clamps on the back legs of both vertical tracks above the third roller to prevent the door from lifting as you unwind the springs Use only approved winding bars available from your dealer Do not use undersized steel rods screw drivers or anything else to unwind the springs Position the ladder just off to the side of the winding cone The winding cone should be easy to reach without putting your body directly in front of it Step 2 Insert a winding bar into one of the holes in the winding cone Exert upward pressure Using caution loosen the two 2 set screws in the winding cone Be prepared to support the full torsional force of the spring when the set screws are loosened Step 3 Once set screws are loose slowly and carefully lower the winding rod until it rests against the door Insert other winding bar into the upper hole Push up and remove lower bar Carefully lower upper winding bar 1 4 turns at a time until it rests against the door Repeat process until all tension is relieved If your door is equipped with two 2 torsion springs follow the same procedure to relieve tension on the second spring Step 4 Remove vice clamps from tracks unbolt torsion shaft assembly and remove from work area NOTE Continue with P4 on page 9 after FIRMLY HOLD WINDING BAR
15. 67 for Consumer Assistance or online at www wayne dalton com INSTALLATION Nylon Center Bushing Tools Needed Slide the nylon center bushing into the TORSION stationary spring cone at the end of the SPRING 9 16 Socket spring and align the stationary spring cone s with the holes in the center STATIONARY Ratchet Wrench bearing bracket Secure the spring s to CENTER BEARING SPRING CONE the center bearing bracket with BRACKET 9 16 Wrench 2 3 8 16 x 1 1 2 hex head bolts and 2 3 8 16 nuts IMPORTANT SPRINGS UNDER TENSION CAN BE DANGEROUS IMPORTANT THE SPRING WARNING STATIONARY TAG S SUPPLIED MUST BE SECURELY SPRING CONE N J ATTACHED TO THE STATIONARY SPRING y M ims NYLON CENTER j BUSHING CONE IN PLAIN VIEW SHOULD A REPLACEMENT SPRING WARNING TAG TORSION SPRING BE REQUIRED CONTACT WAYNE DALTON CORP FOR FREE REPLACEMENTS CENTER BEARING BRACKET 2 3 8 16 NUT TORSION SPRING x JO 2 3 8 16 X 1 1 2 HEX HEAD BOLT 22 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Counterbalance Cables Release the vice grips from the ends of the cables and thread the counterbalance cables around the back side of
16. ACT GUN TO WIND SPRING S i VGE CLANPS INNER RAIL OF TRACK Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 23 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed Power Drill 3 16 Drill Bit 7 16 Socket Driver Phillips Head Screwdriver Winding Torsion Spring s Position a ladder slightly to the side of spring so that the winding cone is easily accessible yet your body is not in direct line with the winding bars Check the label attached to the spring warning tag for the required number of complete turns to balance your door 6 6 Door Height Approx 7 Turns 70 Door Height Approx 7 1 2 Turns 8 0 Door Height Approx 8 3 4 Turns A WARNING PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS ENSURE YOU RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTALLATION INSTRUCTIONS OTHERWISE THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY Alternately inserting the winding bars into the holes of the spring s winding cone rotate the winding cone upward toward ceiling 1 4 turn at a time until the required number of complete turns for your door height is achieved As the last 1 4 turn is achieved secur
17. AREFULLY OTHERWISE SEVERE OR FATAL INJURY COULD RESULT If you have an existing door follow the instructions to identify which counterbalance removal is necessary The process of removing an existing door begins by identifying it s counterbalance system If you are not removing an existing door proceed to PREPARING THE OPENING on page 10 Generally you will find three 3 types of counterbalance systems Extension Spring Wayne Dalton exclusive TorqueMaster and Torsion counterbalance system see pages 6 9 For more technical information regarding the opening preparation installation and use of your garage door and opener you can go to www dasma com and click on Publications and then Technical Data Sheet Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 5 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Torsion Spring Removal For Standard Lift Tools Needed AMY NTT TORSION SPRING ASSEMBLY Recommended FAILURE TO USE APPROVED tools from WINDING BARS CAN CAUSE SPRING page 5 ENERGY TO BE RELEASED SUDDENLY RESULTING IN SEVERE OR FATAL INJURY A WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE A POWERFUL SPRING RELEASING IT S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY Do not release the torsion spring tension unless you are
18. Dry glazing with a clean damp chamois Kerosene may be used to remove grease and oil When using kerosene for cleaning purposes make sure that you are familiar with it s properties using it only in a well ventilated area away from any sources of sparks and or fire DO NOT USE Window cleaning fluids scouring compounds gritty cloths gasoline or solvents such as alcohol acetone carbon tetrachloride etc 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 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 advi
19. F ROLLER and tightening the other lag screws YZ Push the vertical track against the rollers so that the rollers are touching the deepest part of the curved side of the track see illustration Tighten all aT the carriage bolts and nuts VERTICAL TRACK Repeat for opposite side 1 11 16 TO 1 3 4 TOP SECTION FLAGANGLE 18 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed 9 16 Socket 7 16 Socket Ratchet Wrench 9 16 Wrench Level Hammer Tools Needed 7 16 Wrench Attaching Horizontal Track to Adjustable Flagangle To install horizontal track place the curved end over the top roller Align the bottom of the horizontal track with the vertical track Hand tighten the horizontal track to the flagangle with 2 1 4 20 x 5 8 carriage bolts and 2 1 4 20 flange hex nuts Level the horizontal track assembly and bolt the horizontal angle to the slot in the flagangle using 1 3 8 16 x 3 4 hex head bolt and 1 3 8 16 hex nut Repeat for other side Remove the nail that was temporarily holding the top section in place installed in Step 9 IMPORTANT FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMA
20. GE TO TOP SECTION A WARNING DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR AS OUTLINED IN STEP 19 OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY Adjusting Top Brackets With horizontal tracks installed you can now adjust the top brackets Vertically align the top section of the door with the lower sections Once aligned position the roller in the top bracket slide out against the horizontal track Maintaining the slide s position tighten the 2 1 4 20 flange hex nuts to secure the top bracket slide to the top bracket base Repeat for other side INCORRECT TOP SECTION FLAGANGLE N 2 1 4 20 FLANGE HEX NUTS 1 3 8 16 HEX NUT SECTION ills HORIZONTAL i TRACK 2 1 4 20 X 5 8 CARRIAGE BOLTS VERTICAL TRACK HORIZONTAL HORIZONTAL TRACK TOP ROLLER TOP BRACKET SLIDE 2 1 4 20 FLANGED HEX NUTS Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 19 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com INSTALLATION Tools Needed Power Drill 7 16 Socket Driver 9 16 Socket Ratchet Wrench 9 16 Wrench Tools Needed Power Drill 7 16 Socket Driv
21. NG A TROLLEY TYPE GARAGE DOOR OPENER 2 Saw Horses TO THIS DOOR A WAYNE DALTON OPENER TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR ALONG WITH ANY U BARS PROVIDED WITH THE DOOR THE INSTALLATION OF THE OPENER MUST BE ACCORDING TO MANUFACTURER S INSTRUCTIONS AND Zz FORCE SETTINGS MUST BE ADJUSTED ij NOTE For retro fit applications the operator bracket must be aligned with an existing operator If no u bar is installed Locate the center of the top section and attach the operator bracket as shown in the illustration using 6 1 4 20 x 5 8 self drilling screws If u bar is installed Remove but retain 4 to 6 1 4 20 x 7 8 self drilling screws from the center of the u bar Locate the center of the top section and slide operator bracket under u bar till the operator bracket is seated against the u bar flange Attach the operator bracket using 6 1 4 20 x 5 8 self drilling screws as shown Reattach the u bar using the self tapping screws removed previously OPERATOR BRACKET gt ALIGNED WITH TOP OF SECTION SIDE VIEW KAn 6 1 4 20 X 5 8 SELF DRILLING SCREWS pos 1 4 20 X 7 8 SELF DRILLING SCREWS OPERATOR BRACKET OPERATOR BRACKET
22. RTANT USE THE 5 16 X 2 TAMPER RESISTANT LAG SCREW ONLY IF MOUNTING SURFACE MOUNTED OVER MASONRY TAMPER RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BEARING BRACKET HORIZONTAL ANGLE 2 3 8 16 X 3 4 HEX HEAD BOLTS 2 5 16 X 2 LAG SCREWS Z MOUNTING SURFACE S EQUAL DISTANCE A CENTER BEARING BRACKET HORIZONTAL LINE CENTER OF END BEARING BRACKET CENTER BEARING BRACKET MOUNTING SURFACE 5 16 x 2 al Q LAG SCREWS HORIZONTAL LINE M b 1 5 16 X 2 TAMPER RESISTANT LAG SCREW OR 1 5 16 X 2 LAG SCREW Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Torsion Spring Assembly NOTE Right and left hand is always determined from inside the building looking out Tools Needed none NOTE Identify the springs provided as either right hand wound red winding cone which goes on the LEFT HAND SIDE or left hand wound black winding cone which goes on the RIGHT HAND SIDE Facing the inside of the door lay the torsion tube on the floor Lay the spring with the black color coded winding cone and the black color coded cable drum at the right hand end of the tube Lay the spring with the red color coded wind
23. S AND completing this step CAUTIOUSLY LOOSEN SET SCREWS 6 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed Recommended tools from page 5 TorqueMaster Spring Removal A TorqueMaster spring system can be identified by the end brackets For single spring applications the right hand end bracket will always have a drive gear counter gear counter cover and a winding bolt head The left hand end bracket will have no gears counter cover or winding bolt head The hole for the winding bolt head will be plugged For double springs both the right hand and left hand end brackets will always have a drive gear counter gear counter cover and a winding bolt head IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT Step 1 If you have a black counter cover Place a mark on the drive gear tooth and an adjacent mark on the right hand end bracket Fig 1 Loosen the lock nut using a 7 16 wrench and continue with step 2 If you have a gray counter cover Loosen the lock nut using a 7 16 wrench and continue with step 2 Step 2 Using an electric drill High torque gear reduced to 1300 rpm preferred with a 7 16 hex head driver unwind the right hand winding bolt head
24. Wayne Dalton 9800 Series Torsion Spring Installation Instructions and Owner s Manual Portland Source Plant Copyright 2009 Wayne Dalton Corp IMPORTANT NOTICE Read these instructions carefully before attempting installation If in question about any of the procedures do not perform the work Instead have a qualified door agency do the installation or repairs Part No 326091 REV2 08 03 2009 Table of Contents mponantsareiviinstiuctions 2 eelo MOCE ee e E E E E E 3 DOO SAO EEEO aesae 4 o ne a e eea e E E a S 5 AEAEE EE E E cree E ieee 5 10 ReMmovingmihe Old DOO ra ME 5 9 PrepanngomiheiOpeninor e sees ree 10 Installationgeerrsses erste o HE 11 26 Optionaliinstalations eee eee 27 28 Side lock mrem 27 ti METO E RE E 27 Trolley Operator e 28 Maintenance lt mn 29 30 cleaning man eee 29 Banners tu HOT 29 30 Warrant eee 31 Gustomer Service NUmber eee 32 Definition of key words used in this manual A 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 A WARNING READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION IF IN QUESTION ABOUT
25. ached to the wall above the header at the center of the opening The mounting surface must be 2 x 6 lumber minimum Select southern yellow pine lumber Do not use lumber marked as spruce WEATHER pine fur or SPF a SEAL The mounting surface must be securely attached to block or concrete wall with four 4 3 8 masonry anchors or four 4 5 16 x 4 lag screws for a wood structure x JAMB 1 8 TO 1 4 NOTE Drill a 3 16 pilot hole in the mounting surface to avoid FULLY ADJUSTABLE TRACK splitting the lumber Do not attach the mounting surface with nails DOOR DOOR STOP STOP WEATHER SEAL DOOR STOP Cut weather seal or door stop may not be included to fit the jambs and header DOOR Baa Align the edge of the weather seal or door stop an 1 8 to 1 4 ai SECTION a inside the edge of the opening Temporarily nail approximately JAMB wi 18 TO 1 4 12 to 18 apart the weather seal apart or door stop to the jambs to keep the bottom section from falling out of the opening HEADROOM REQUIREMENT during installation NOTE Do not permanently attach weather seal or door stop to the TRACK TYPE TorqueMaster jambs at this time Permanent installation will be done in Step 19 m HEADROOM REQUIREMENT Headroom is defined as the space needed above the top of the door for tracks springs etc to allow BACKROOM REQUIREMENT the door to open properly If the door is to be motor operated 2
26. after completing this step Removing the Old Door Having removed the counterbalance system the door can now be disassembled Start by first removing the top row of hinges With assistance hold the top section to keep it from falling and remove the top brackets With assistance lift the top section out of the opening and remove it from the work area Repeat for all remaining sections After door is disassembled unbolt both track assemblies from the jambs and remove all material from the work area You can neatly dispose of the old door by placing it in the carton of your new door Clean up area and complete Preparing the Opening P5 on page 10 before installing the new door TOP BRACKET REMOVE LAG SCREW a FROM SAFETY CABLE IF INSTALLED REPEAT FOR OPPOSITE SIDE BOTTOM SECTION DOOR OPEN CAREFULLY REMOVE S HOOK AND COUNTERBALANCE CABLE REPEAT FOR THE OPPOSITE SIDE HORIZONTAL ANGLE HORIZONTAL TRACK Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com 9 PRE INSTALLATION i i HEADER BOARD SURFACE 2 X 6 Preparing the Opening 2 X 6 LUMBER A __ LUMBER MINIMUM RECOMMENDED Tools Needed A WARNING ace ae MOUNTING PAD TO
27. arriage bolts and 2 1 4 20 flange hex nuts Secure the flange nuts after 2 1 4 20 flagangle spacing is complete Step 9 FLANGE HEX NUTS aA 2 1 4 20 X 5 8 CARRIAGE BOLTS d i p None M M VERTICAL VA TRACK Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 11 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Installing Fully Adjustable Jamb Brackets FULLY ADJUSTABLE JAMB BRACKET 5 Tools Needed To attach the bottom jamb bracket JB 1 locate the first set of quick install features of the vertical track Align the slot in the jamb bracket with the slot above the quick install features in the vertical track The long side of the bracket is placed against the track None Fasten the jamb bracket finger tight using 1 1 4 20 x 5 8 carriage bolt 1 1 4 20 X 5 8 and 1 1 4 20 flange hex nut CARRIAGE BOLT To attach the top jamb bracket JB 1 j Tem locate the third set of quick install 1 1 4 20 features of the vertical track Align FLANGE QUICK INSTALL the slot in the jamb bracket with the HEX NUT FEATURE slot above the quick install features in the vertical track The long side of the bracket is placed against the track Fasten the jamb bracket finger tight
28. ce is always determined by 1 being the bottom section to 3 or 4 being the highest intermediate section See views to the right If the stamp on the end hinge is illegible refer to the section side view illustration to the right The section side view illustration shows the end hinge profile of all the sections and can also be used in conjunction with identifying each sections The BOTTOM SECTION can be identified by 1 end hinges the factory attached bottom astragal and the bottom bracket warning labels on each end stile The LOCK SECTION can be identified by a 2 end hinge The INTERMEDIATE SECTION can be identified by 3 end hinges The section will have a warning label attached to either the right or left hand end stile NOTE 4 End hinges are used on the fourth section of five section doors The TOP SECTION can be identified with no pre installed end or center hinges and U bar attached to the top section TYPICAL HINGE STAMPING LOCATION TOP SECTION WARNING LABEL MAY BE ON RIGHT OR LEFT HAND SIDE INTERMEDIATE SECTION LOCK SECTION BOTTOM BRACKET WARNING LABELS BOTTOM SECTION ASTRAGAL SECTION SIDE VIEW gt 13 8 Ne ASTRAGAL BOTTOM BRACKET Please Do Not Re
29. counterclockwise Fig 2 and count the number of turns the mark on the drive gear passes the adjacent mark on the end bracket Referencing the chart below by door height stop unwinding the spring once the counted turns have reached the listed number of turns 6 0 Door Height 6 3 Door Height 6 5 Door Height 6 6 Door Height 6 8 Door Height 2 turns 6 9 Door Height 2 turns 7 0 Door Height T 3 Door Height T 6 Door Height 7 9 Door Height 8 0 Door Height 18 turns CAUTION DO NOT USE IMPACT GUN TO UNWIND SPRINGS IMPORTANT DO NOT REFERENCE THE COUNTER COVER WHEN COUNTING THE NUMBER OF TURNS BEING UNWOUND ON THE SPRING BUT FOLLOW THE INSTRUCTIONS ABOVE Step 3 Verify that spring tension has been released by pulling the counterbalance cable on the right hand cable drum away from the header Fig 3 If spring tension has been released the cable will be loose In addition the TorqueMaster Spring Tube should be free to rotate in either direction LOOSEN LOCK RIGHT HAND CABLE DRUM TORQUEMASTER SPRING TUBE PRY COUNTER GEAR AND COUNTER COVER FROM END BRACKET USING FLAT TIP SCREWDRIVER COUNTER GEAR COVER RIGHT HAND END BRACKET PLACE MARK ON END BRACKET AND DRIVE GEAR TOOTH BEFORE UNWINDING SPRINGS END BRACKET RIGHT HAND WINDING BOLT HEAD ELECTRIC DRILL WITH 7 16 HEX DRIVER DO NOT USE IMPACT GUN CHECK CABLE TENSION
30. djust weather seal or door stop if necessary Now permanently attach the weather seal or door stop to both door jambs and header Temporarily attached in PREPARING THE OPENING on page 10 Avoid pushing weather seal or door stop too tightly against face of door A WARNI NG HORIZONTAL TRACK PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS ENSURE YOU RE WINDING IN THE DOOR EDGE Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 25 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed 26 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts Rear Support Continued 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 To adjust spring tension fully close door Apply locking pliers to track above third roller Insert a winding bar into the winding cone Push upward on the winding bar 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 r
31. ely hold winding bar while tightening both set screws in winding cone to 14 15 ft Ibs of torque Once set screws contact the tube tighten screws one full turn Carefully remove winding bar from winding cone Proceed to wind the second spring in the same manner While holding the door down to prevent it from rising unexpectedly in the event the spring s were overwound carefully remove the locking clamps from the torsion tube and the vertical tracks IMPORTANT CAUTIOUSLY REMOVE LOCKING PLIERS FROM THE TORSION TUBE AND LOCKING CLAMPS FROM THE VERTICAL TRACKS Adjustments to the required from the number of turns stated may be necessary If door raises off floor under spring tension alone Reduce spring tension until door rests on the floor If the door is hard to raise or drifts down on its own add spring tension An unbalanced door such as this can cause garage door opener operation problems APPROVED WINDING BARS SPRING WINDING CONE APPROVED TORSION WINDING BARS TUBE 24 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com 1 9 Rear Support DOOR IN THE UP POSITION Tools Needed A WARNING WARNING ih Ratchet Wrench KEEP HORIZONTAL TRACK
32. epeat for the other side Recheck door balance DO NOT ADJUST MORE THAN 1 2 TURN FROM THE RECOMMENDED NUMBER OF TURNS 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 Refer to P1 on page 6 Torsion Spring Removal For Standard Lift and recheck the following the items 1 Check the door for level 2 Check the torsion tube for level 3 Check the track spacing 4 Check the counterbalance cables for equal tension 5 Check the track for potential obstruction of the rollers 6 Clamp locking pliers onto track and rewind springs IMPORTANT IF DOOR STILL DOES NOT OPERATE PROPERLY THEN CONTACT A QUALIFIED DOOR AGENCY 2 SOUND FRAMING M Pa HORIZONTAL TRACK a HORIZONTAL TRACK 3 5 16 BOLTS amp NUTS j PERFORATED ANGLE oeoooooooo oooooboooopooo o EMBERS lt PERFORATED ANGLE BOLTED USING 2 5 16 X 1 5 8 HEX HEAD LAG SCREWS TO CEILING MEMBER AND PARALLEL TO WIDTH OF DOOR BOLT MUST EXTEND INTO THE TRACK TO SERVE AS A ROLLER STOP lt lt SOUND FRAMING MEMBERS M PERFORATED ANGLE BOLTED USING 2 5 16 X 1 5 8 HEX HEAD LAG SCREWS TO CEILING MEMBER AND PARALLEL TO WIDTH OF DOOR BOLT MUST EXTEND INTO pec THE TRACK TO SERVE AS A ROLLER STOP WEATHER SEAL You May Need
33. er Level Tape Measure Pencil 1 4 Torx Bit 20 Torsion End Bearing Brackets End bearing brackets are right and left Using the upper slots in the end bearing bracket position above the flagangle and secure the end bearing bracket to the horizontal angle using 2 3 8 16 x 3 4 hex head bolts and 2 3 8 16 nuts Once the bracket is secured to the horizontal angle secure the top of the end bearing bracket to the jamb using 2 5 16 x 2 lag screws Repeat for other side NOTE Right and left hand is always determined from inside the garage looking out Center Bearing Bracket Measure to locate the center of the door and mark a vertical pencil line on the mounting surface above the door to indicate the center line of the door Then measure from the center of the bearing in one of the end bearing brackets DOWN to the top of the door Using that dimension measure UP from the top of the door and mark a horizontal pencil line on the mounting surface intersecting the vertical pencil line Now align the edge of the center bearing bracket along the vertical pencil line on the mounting surface Center the bearing bracket on the horizontal line This will ensure the torsion tube is level between the center and end bearing brackets Attach the center bearing bracket in this location to the mounting surface using 2 5 16 x 2 lag screws and 1 5 16 x 2 tamper resistant lag screw IMPO
34. ing cone and the red color coded cable drum at the left hand end of the tube NOTE The set screws used on all torsion counterbalance winding cones and cable drums are now colored red DO NOT identify right and left hand by the set screw color Slide the nylon center bushing onto the torsion tube followed by the springs and cable drums The nylon center bushing springs and cable drums must be positioned as shown With assistance pick up the torsion assembly and slide one end of the tube through one end bearing bracket Lay the torsion tube into the center bearing bracket and slide the other end of the tube into the opposite end bearing bracket Position the torsion tube so that equal amounts of the tube extend from each end bearing bracket 7 7 RIGHT HAND CABLE DRUM BLACK LEFT HAND CABLE DRUM NYLON CENTER BRACKET BUSHING lt _ RIGHT lt HAND CABLE DRUM BLACK LEFT HAND WOUND BLACK WINDING CONE RIGHT HAND SIDE NYLON CENTER BRACKET BUSHING RIGHT HAND WOUND RED WINDING CONE LEFT HAND SIDE LEFT HAND CABLE aN DRUM RED TORSION TUBE EQUAL SPACING TORSION ASSEMBLY TORSION END ASSEMBLY BEARING BRACKET Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 21 You May Need You can reach us Toll Free at 1 888 827 36
35. lat tip REMOVE screwdriver Fig 7 BOTTOM LAG amp CAUTION THE WINDING SHAFT MAY SEREN ROTATE WHEN REMOVING THE END BRACKET AND DRIVE GEAR HOLD THE Step 7 Repeat Step 4 for the left hand A un DM side Holding the left hand end bracket LOCKING PLIERS steady with locking pliers carefully pry the end bracket off the winding shaft using a flat tip screwdriver Fig 7 Step 8 Remove the two 2 lag bolts attaching the center bracket assembly to ne header board Fig 8 7 PRY END BRACKET FROM WINDING Step 9 Lift the right hand side of the E SHAFT USING A FLAT TIP SCREW TorqueMaster Spring Tube and slide the DRIVER AND LOCKING PLIERS cable drum off Realign the groove in the Due winding shaft with the round notch in the IX flagangle and drape the counterbalance cable with drum over the flagangle Lift the left hand side of the TorqueMaster CENTER Spring Tube and slide the cable drum BRACKET REMOVE CABLE DRUM AND and winding shaft off Fig 9 Drape the ASSEMBLY WINDING SHAFT counterbalance cable with drum over the L flagangle Lift the TorqueMaster spring assembly off the flagangles and out of the doorway Unhook the counterbalance cables from the bottom brackets and p S N f remove all parts from the work area L JM yA NOTE The cable drums may be difficult to remove If so twist the cable drum to aid a 715 uff in removal lb TTORQUEMASTER NOTE Continue wi
36. n iii Peeling cracking chalking or fading of the factory applied coating from the time of installation If the door is re stained or re painted the warranty for the factory applied coating is void The Manufacturer warrants the garage door hardware except springs and the tracks of the above described door for as long as you own the door against defects in material and workmanship subject to all the terms and conditions below The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Lifetime Limited Warranty against defects in material and workmanship for a period of ONE 1 YEAR from the date of installation After a period of TWENTY 20 YEARS from time of installation replacement of Lifetime Limited Warranty materials will be pro rated at 50 per cent of Manufacturer s published list pricing at time of claim and you must pay this amount This Limited Warranty is extended only to the person who purchased the product and continues to own the premises where the door is installed as his her primary residence Buyer This Limited Warranty does not apply to residences other than primary or to commercial or industrial installations or to installations on rental property even when used by a tenant as a residence This Limited Warranty is not transferable to any other person even when the premises is sold nor does it extend benefits to any other person As a result this Limited Warranty d
37. nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy The liability of the Manufacturer whether in contract or tort under warranty product liability or otherwise will not go beyond the Manufacturer s obligation to repair or replace at its option as described above THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES including but not limited to damage or loss of other property or equipment personal injury loss of profits or revenues business or service interruptions cost of capital cost of purchase or replacement of other goods or claims of third parties for any of the foregoing e 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 law
38. oes NOT apply to any person who purchases the product from someone other than an authorized Wayne Dalton dealer or distributor The Manufacturer will not be responsible for any damage attributable to improper storage improper installation or any alteration of the door or its components abuse damage from corrosive fumes or substances salt spray or saltwater air fire Acts of God failure to properly maintain the door or attempt to use the door its components or related products for other than its intended purpose and its customary usage This Limited Warranty does not cover ordinary wear This Limited Warranty will be voided if any holes are drilled into the door other than those specified by the Manufacturer THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON MOSS ACT NO WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY ABOVE Some States do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you Any claim under this Limited Warranty must be made in writing within the applicable warranty period to the dealer from which the product was purchased Unless the dealer is no longer in business a written claim to the Manufacturer will be the same as if no claim had been made at all At the Manufact
39. ou May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com INSTALLATION 1 Top Brackets Tools Needed To install the L shaped top brackets align the bottom holes in the top bracket base with the second set of holes from the end cap AND SET OF HOLES 7 Sce p FROM BOTTOM Power Drill Fasten using 4 1 4 14 x 5 8 self tapping screws Secure the top bracket slide to the bracket base loosely using 2 1 4 20 x 5 8 carriage bolts and 2 1 4 20 flanged hex nuts The top bracket slide will be tightened 0 o and adjusted in Step 11 Insert rollers TOP BRACKET BASE into top bracket slide Repeat for other side of TOP SECTION 4 1 4 14 x 5 8 SELF TAPPING screws 2ND SET OF HOLES FROM BOTTOM 2 1 4 20 x 5 8 CARRIAGE BOLTS TOP BRACKET SLIDE TOP SECTION 2 1 4 20 FLANGE HEX TOP SECTION 16 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com IF NO U BAR IS INSTALLED Operator Bracket OPERATOR BRACKET CENTERED IN THE Tools Needed NOTE If installing a trolley type operator complete this step If not skip this step Power Dall and continue with Step 9 7 16 Socket Driver IMPORTANT WHEN CONNECTI
40. roper applications of coatings and disposal of containers Pay particular attention to acceptable weather and temperature conditions in which to paint Fiberglass garage door finishing directions 1 It is recommended that the doors 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 preformed 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 The top coat on factory finished doors 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 a Clean surfaces with soap and water or wipe down with mineral spirits or Naptha Light scuff sanding may be required using Scotch Brite b Apply a commercial brand of exterior grade top coat following the manufacturer instructions To strip the existing coating from the door use a commercial grade paint stripping products To paint over the existing paint clean per the instructions listed above and apply any commercially available exterior grade water 30 based or oil based paint Please Do Not Return This Product To The Store Call Us Directly Our Trained Technician
41. s Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Lifetime Limited Warranty Model 9800 Subject to the terms and conditions contained in this Lifetime Limited Warranty Wayne Dalton Corp Manufacturer warrants the sections of the door for as long as you own the door with the exception of the items that follow which is described at the top of this page These exceptions will be warranted for a period of THREE 3 YEARS from the date of installation against i Delamination of the fiberglass skin or peeling of the original factory applied coating on the door as a result of a defect in the original fiberglass skin where the door sections and the original fiberglass skin and factory applied coating a have not been subjected to adverse atmospheric conditions or contaminates such as salt water or other marine environment or to toxic or abrasive substances including those in the air b have been maintained in compliance with Manufacturer s recommendations and c have not been subject to physical abrasion impacted by a hard objects or have been punctured ii The door becoming inoperable due to rust through of the steel skin backer from the core of the door section caused by cracking splitting or other deterioration of the steel skin or due to structural failure caused by separation or degradation of the foam insulatio
42. s of the State of Ohio USA to the extent permitted by law e This Limited Warranty gives you specific legal rights and you may also have other rights which may vary from State to State Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 31 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Covered by one or more of the following Patents 5 408 724 5 409 051 5 419 010 5 495 640 5 522 446 5 562 141 5 566 740 5 568 672 5 718 533 6 019 269 6 089 304 6 644 378 6 374 567 6 561 256 6 527 037 6 640 872 6 672 362 6 725 898 6 843 300 6 915 573 6 951 237 7 014 386 7 036 548 7 059 380 7 121 317 7 128 123 7 134 471 7 134 472 7 219 392 7 254 868 Canadian 2 384 936 2 477 445 2 495 175 2 507 590 2 530 701 2 530 74 2 2 532 824 Other US and Foreign Patents pending Please Do Not Return This Product To The Store Call Us Toll Free Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need 888 827 3667 Thank you for your purchase www wayne dalton com 32
43. sable 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 After surface has been properly prepared it must be allowed to dry thoroughly then coated immediately with a 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 Repainting of finish painted steel doors cannot be warranted as this condition is totally beyond the door manufacturer s control Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts 29 You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com MAINTENANCE Painting Continued If the finish painted steel door surface has a textured surface representing wood grain stucco etc this step should not be attempted as danger of exposing substrate is greatly increased Consult a professional coatings contractor if in doubt about any of the above directions Follow directions explicitly on the paint container labels for p
44. th P4 on page 9 after E completing this step 2 5 16 X 1 5 8 DRAPE CABLE ABUS Minaa HEX HEAD LAG TOP OF FLAGANGLE SCREWS Fig 8 Fig 9 8 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed Recommended tools from page 5 Tools Needed Recommended tools from page 5 Extension Spring Removal Step 1 Raise the door to the fully open position and place vice clamps to the back legs of both vertical tracks below the bottom rollers to prevent the door from falling By opening the door you release most of the spring tension Carefully unfasten the S hook from the horizontal angle Remove cable sheave and extension spring Repeat for the other side If safety cables are running through the extension springs remove them also Remove parts from work area Step 2 Holding door in the open position remove the vice clamps be prepared to support the entire weight of the door Garage doors can weigh 200 400 pounds With assistance carefully lower the door by grasping the door firmly by it s lift handles Do not place fingers or hands near joints between sections or between bottom of door and floor Otherwise severe injury could result NOTE Continue with P4 on page 9
45. the cable drums and verify that there are no cable Y V obstructions Hook the cables into the JJ HOOKED IN drums Slide the left hand cable drum T CABLE DRUM y against the left hand end bearing bracket and tighten the set screws in the drum to 14 15 ft lbs of torque Once set screws contact the tube tighten screws one full turn Rotate the left hand drum and torsion LEFT END BEARING BRACKET tube until cable is taut Attach vice grips to torsion tube and brace vice grips against BERN jamb to keep cable taut Slide the right hand cable drum against the right hand end bearing bracket and rotate drum until cable is taunt Tighten set screws in right hand cable drum to 14 15 ft Ibs of torque Once set screws contact the tube tighten screws one full turn Tools Needed Vice Grips 3 8 Wrench SET TORSION y SCREWS TUBE INSTALLATION IMPORTANT CHECK EACH CABLE MAKING SURE BOTH ARE SEATED PROPERLY ON u THE CABLE DRUMS AND HAVE EQUAL CABLE TENSION Securing Door for Spring Winding Tools Needed Place vice clamps onto both vertical 2 Vice Clamps tracks just above the third roller This is to prevent the garage door from raising while winding torsion springs 4 WARNING n PLACE VICE CLAMPS ABOVE FAILURE TO PLACE VICE x ERTICAL TRACKS CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY IMPORTANT DO NOT USE IMP
46. turn This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Required E w am POWER DRILL RATCHET WRENCH PLIERS WIRE CUTTERS TAPE MEASURE 1 8 3 16 DRILL BITS 2 A L AE PHILLIPS HEAD SCREWDRIVER FLAT TIP SCREWDRIVER PENCIL NEEDLE NOSE PLIERS GLOVES ef La 7 16 1 2 9 16 7 16 SOCKET DRIVER 3 8 7 16 1 2 9 16 SAFETY GLASSES SOCKETS WRENCHES f lt a A PN J VICE GRIPS PAIR VICE CLAMPS SAW HORSES PAIR STEP LADDER Removing An Old Door A WARNING IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED DO NOT ATTEMPT TO WORK ON IT BUT HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK OTHERWISE SEVERE OR FATAL INJURY COULD RESULT A WARNING DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO PREVENT UNINTENDED DOOR OPERATION OTHERWISE SEVERE OR FATAL INJURY COULD RESULT A WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE A POWERFUL SPRING RELEASING IT S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY A WARNING IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS OR SEVERE INJURY COULD RESULT A WARNING REMOVING AN EXISTING DOOR CAN BE DANGEROUS FOLLOW INSTRUCTIONS ON PAGES 6 10 REMOVING AN OLD DOOR PREPARING THE OPENING C
47. urer s option pursuant to the dealer having notified the Manufacturer of a warranty claim a service representative may inspect the product on Site or Buyer may be required to return the product to the Manufacturer at Buyer s expense Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty the Manufacturer will cause the defective product to be repaired or replaced The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer subject to applicable law THE REMEDY WILL COVER ONLY MATERIAL THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES SUCH AS FIELD SERVICE LABOR FOR REMOVAL INSTALLATION PAINTING SHIPPING ETC Any repairs or replacements arranged by Manufacturer will be covered by and subject to the terms conditions limitations and exceptions of this Limited Warranty provided however that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed and this Limited Warranty will expire at the same time as if there had been no defect If a claim under this Limited Warranty is resolved in a manner other than described in the immediately preceding paragraph then neither this Limited Warranty
48. using 1 1 4 20 x 5 8 carriage bolt and 1 1 4 20 flange hex nut QUICK INSTALL 1 P VERTICAL FEATURE TRACK 12 Please Do Not Return This Product To The Store Call Us Directly Our Trained Technicians Will Answer Your Questions and or Ship Any Parts You May Need You can reach us Toll Free at 1 888 827 3667 for Consumer Assistance or online at www wayne dalton com Tools Needed None Tools Needed Level Counterbalance Cables IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE GARAGE LOOKING OUT NOTE For door section identification see page 4 Uncoil the counterbalance cables and slip the loop at the ends of the cables over each milford pin on the bottom section Insert a roller into bottom bracket of the bottom section and insert another roller at 1 end hinge at the top of the bottom section Repeat for other side NOTE Verify astragal bottom seal is aligned with door section If there is more than 1 2 excess astragal on either side trim astragal even with door section Bottom Section Before installing the bottom section the weather seal may not be included must be installed see PREPARING THE OPENING on page 10 Center the bottom section in the door opening Level section using wooden shims if necessary under the bottom section COUNTERBALANCE la CABLE BOTTOM SECTION MILFORD PIN
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