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Wayne-Dalton 341785 User's Manual

1. 1 1 4 20 X 9 16 TRACK BOLT 1 5 16 WASHER 1 1 4 TOP CURVE OF LOW HEADROOM HORIZONTAL TRACK a To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com 20 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer TOP BRACKET ASSEMBLY Top Brackets Tools Needed Remove but retain 2 4 1 4 14 x 7 8 self drilling screws from the right side of the u bar allowing enough room to slide the top bracket between the section and the u bar Power Drill 7 16 Socket Driver Insert a roller into the low headroom top bracket Slide the low headroom top bracket assembly between the u bar 3 1 4 20 X 7 8 SELF and section as shown TOP SECTION DRILLING SCREWS Hammer Twist the roller into the upper track Align the edge of the top bracket assembly parallel to the section edge Secure the top bracket and u bar to the section with 3 1 4 20 x 7 8 self drilling screws through the upper and TOP BRACKET lower slots of the bracket as shown ASSEMBLY Finish re attaching the u bar using the 1 4 20 x 7 8 self drilling screws removed previously Repeat for left hand side
2. 3 5 16 X 1 5 8 LAG SCREWS TOP SECTION CENTER BEARING BRACKET VERTICAL LINE CENTER BEARING gt VERTICAL LINE To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Tools Needed none Torsion Spring Assembly NOTE Right and left hand is always determined from inside the garage looking out Facing the inside of the door lay the torsion tube on the floor Lay the spring with the black color coded winding cone and the red color coded cable drum at the left hand end of the tube Lay the spring with the red color coded winding cone and the black color coded cable drum at the right hand end of the tube NOTE Identify the springs provided as either right hand wound red winding cone which goes on the RIGHT HAND SIDE or left hand wound black winding cone which goes on the LEFT HAND SIDE NOTE The set screws used on all torsion counterbalance winding cones and cable drums are now colored red DO NOT identify right and left hand by the set screw color Slide the nylon center bushing onto the torsion tube followed by the springs The nylon center bushing and springs must be positioned as shown With assistance pick up the torsion assembly and slide one end of the tube through one end bearing bracket Lay the torsion tube into the center bearing bracket and slide the other end of the tube into t
3. INSTALLATION Remove the nail that was temporarily holding the top section in place IMPORTANT FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION A WARNING DO NOT RAISE DOOR UNTIL TOP SECTION ON EDGE HORIZONTAL TRACKS ARE O SECURED AT REAR AS OUTLINED IN STEP 21 OR DOOR COULD FALL FROM OVERHEAD POSITION HEADER CAUSING SEVERE OR FATAL INJURY TOP BRACKET ASSEMBLY TOP SECTION Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 21 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Tools Needed Power Drill 7 16 Socket Driver Tools Needed Power Drill 7 16 Socket Driver Level Tape Measure Pencil 1 4 Torx Bit 22 End Brackets NOTE Right and left hand is always determined from inside the garage looking out End bearing brackets are right and left Align bottom edge of left end bracket with the top edge of the flagangle Maintaining this alignment also align the right edge of the end bracket with the right edge of the flagangle Secure end bracket to the jamb us
4. pilot holes d for the lag screws Loosely fasten QUICK INSTALL AND FULLY ADJUSTABLE jamb brackets and flagangles to the FLAGANGLE LAG LOCATIONS jamb using 5 16 x 1 5 8 lag screws QUICK INSTALL Tighten lag screw securing bottom IEE aoron JAMB BRACKET jamb bracket to jamb to maintain 5 8 p SECTION spacing Repeat for the right side A 3 16 Drill Bit Power Drill Tape Measure Level Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 15 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Stacking Sections Tools Needed NOTE For door section identification see Power Drill page 4 LOCK SECTION 7 16 Socket NOTE Make sure hinge leafs are flipped Driver down when stacking another section on top Place rollers in hinge tubes of the second section lock section With assistance lift second section and guide rollers into the vertical tracks Align vertical marks in the upper alignment sticker with the lower alignment sticker on right hand side on the back of door Keep sections aligned and fasten hinges to connect the sections using 1 4 14 x 5 8 self tapping screws Repeat for other section s except top section IMPORTANT WHEN
5. COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED IN SECTIONS P1 P2 AND P3 DO NOT ATTEMPT TO WORK ON IT BUT HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK OTHERWISE SEVERE OR FATAL INJURY COULD RESULT 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 CAREFULLY OTHERWISE SEVERE OR FATAL INJURY COULD RESULT If you have an existing door follow the instructions to identify which counterbalance removal is necessary The process of removing an existing door begins by identifying it s counterbalance system If you are not removing an existing door proceed to PREPARING THE OPENING on page 10 Generally you will find three 3 types of counterbalance systems Torsion spring counterbalance systems Wayne Dalton exclusive TorqueMaster and Extension Spring counterbalance systems For more technical information regarding the opening preparation installation and use of your garage door and opener you can go to www dasma
6. 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 SET SCREWS Step 3 Once set screws are loose slowly and carefully lower the winding rod until it rests against the door Insert other winding bar into the upper hole Push up and remove lower bar Carefully lower upper winding bar 1 4 turns at a time until it rests against the door Repeat process until all tension is relieved If your door is equipped with two 2 torsion springs follow the same procedure to relieve tension on the second spring Step 4 Remove vice clamps from tracks unbolt torsion shaft assembly and remove from work area NOTE Continue with P4 on page 9 after completing this step Z TORSION SPRING ASSEMBLY FIRMLY HOLD WINDING BARS AND CAUTIOUSLY LOOSEN SET SCREWS Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com 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 coun
7. RESULT FROM FAILURE TO FOLLOW INSTRUCTIONS IMPORTANT REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION NOTE Information assuring proper installation of the door AW Ot TO AVOID POSSIBLE INJURY 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 1 READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS 2 Wear protective gloves during installation to avoid possible cuts from sharp metal edges 3 Itis always recommended to wear eye protection when using tools otherwise eye injury could result 4 Avoid installing your new door on windy days Door could fall during the installation causing severe or fatal injury 5 Doors 12 0 wide and over should be installed by two persons to avoid possible injury 6 Operate door ONLY when it is properly adjusted and free from obstructions 7 If adoor 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 o
8. clean water only to remove any loose particles and any soapy film residue Surface scratches which have not exposed the metal substrate can be lightly buffed or sanded with 0000 steel wool or No 400 sand paper to create a smoother surface Care must be taken to not expose the substrate under the paint Once the substrate is exposed the likelihood for rusting is greatly increased If substrate is exposed it must be treated to prevent rust from forming Sand the exposed area lightly and paint with a high quality metal primer specifically intended for galvanized surfaces to protect the area from corrosion Allow for drying time on primer can label before applying topcoat The surface of the factory applied finish that is being painted must not be too smooth or the paint will not adhere to it It is advisable to test in an inconspicuous area to evaluate adhesion If poor adhesion is observed surface preparation for painting the factory applied finish must be repeated until desired results are achieved Again care must be taken to not expose the substrate under the paint STEEL PAINTING After surface has been properly prepared it must be allowed to dry thoroughly and then coated immediately with premium quality latex house paint Follow paint label directions explicitly Oil base or solvent base paints are not recommended Please note that if substrate is exposed and not properly primed painting with latex paint may cause accelerated r
9. 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 by the pre attached u bar and no pre installed end or center hinges on the section TYPICAL HINGE STAMPING LOCATION TOP SECTION WARNING LABEL MAYBE ON RIGHT OR LEFT HAND SIDE INTERMEDIATE SECTION LOCK SECTION BOTTOM BRACKET WARNING LABELS BOTTOM SECTION ASTRAGAL SECTION SIDE VIEW gt 13 8 ASTRAGAL Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Ne BOTTOM BRACKET Tools Required p Ps pd POWER DRILL RATCHET WRENCH PENCIL LEVEL TAPE MEASURE 1 8 3 16 DRILL BITS ZO APO ss APPROVED WINDING PHILLIPS HEAD SCREWDRIVER FLAT TIP SCREWDRIVER 1 4 TORX BIT BARS GLOVES A 7 16 1 2 9 16 7 16 SOCKET DRIVER 7 16 1 2 3 8 9 16 SAFETY GLASSES SOCKETS WRENCHES udo b 4 HAMMER VICE GRIPS VICE CLAMPS SAW HORSES PAIR STEP LADDER Removing An Old Door A WARNING IF YOUR
10. of the steel skin or due to structural failure caused by separation or degradation of the foam insulation iii Peeling cracking chalking or fading of the factory applied coating from the time of installation If the door is re stained or re painted the warranty for the factory applied coating is void The Manufacturer warrants the garage door hardware except springs and the tracks of the above described door for as long as you own the door against defects in material and workmanship subject to all the terms and conditions below The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Lifetime Limited Warranty against defects in material and workmanship for a period of ONE 1 YEAR from the date of installation After a period of TWENTY 20 YEARS from time of installation replacement of Lifetime Limited Warranty materials will be pro rated at 50 per cent of Manufacturer s published list pricing at time of claim and you must pay this amount This Limited Warranty is extended only to the person who purchased the product and continues to own the premises where the door is installed as his her primary residence Buyer This Limited Warranty does not apply to residences other than primary or to commercial or industrial installations or to installations on rental property even when used by a tenant as a residence This Limited Warranty is not transferable to any other person even when th
11. the flagangle 1 4 turn to lock in place Repeat for other side NOTE After completing this step continue with Step 3 VERTICAL VERTICAL TRACK TRACK LEFT HAND TRACK AND FLAGANGLE RIGHT HAND TRACK AND FLAGANGLE Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 11 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Tools Needed None Tools Needed 12 None Attaching Fully Adjustable Flagangle to Vertical Track NOTE If quick install flagangle was installed in Step 1 skip this step and continue with Step 3 If not complete this step Hand tighten the flagangle to the vertical track using 2 1 4 20 x 9 16 large head ribbed track bolts or stud plate if included and 2 1 4 20 flange hex nuts Repeat for other side Secure the flange nuts after flagangle spacing is complete Step 10 Installing Quick Install Jamb Brackets NOTE If you have fully adjustable jamb brackets skip this step and complete Step 4 Measure the length of the vertical tracks Using the jamb bracket schedule determine the placement of the jamb brackets for your door height and track type To install the jamb brackets align the twistlock tab on the quick install jamb bracket with t
12. written claim to the Manufacturer will be the same as if no claim had been made at all At the Manufacturer s option pursuant to the dealer having notified the Manufacturer of a warranty claim a service representative may inspect the product on Site or Buyer may be required to return the product to the Manufacturer at Buyer s expense Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty the Manufacturer will cause the defective product to be repaired or replaced The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer subject to applicable law THE REMEDY WILL COVER ONLY MATERIAL THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES SUCH AS FIELD SERVICE LABOR FOR REMOVAL INSTALLATION PAINTING SHIPPING ETC Any repairs or replacements arranged by Manufacturer will be covered by and subject to the terms conditions limitations and exceptions of this Limited Warranty provided however that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed and this Limited Warranty will expire at the same time as if there had been no defect If a claim under this Limited Warranty is resolved in
13. Attach door arm to operator bracket OPERATOR installed in Step 9 FRAMING MEMBERS Attach operator rail to suitable mounting surface 2 x 6 lumber minimum Attach operator to ceiling using C O A gt perforated angle Tf IMPORTANT ANGLES MUST BE f SECURELY ATTACHED TO SOUND HE PERFERATED ANGLE FRAMING MEMBER S 30 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Cleaning Your Steel And Fiberglass Garage Door IMPORTANT DO NOT USE A PRESSURE WASHER ON GARAGE DOOR While factory applied finishes on garage doors are durable it is desirable to clean them on a routine basis Some discoloration of the finish may occur when a door has been exposed to dirt laden atmosphere for a period of time Slight chalking may also occur as a result of direct exposure to sunlight Cleaning the door will generally restore the appearance of the finish To maintain an aesthetically pleasing finish of the garage door a periodic washing of the garage door is recommended The following cleaning solution is recommended A mild detergent solution consisting of one cup detergent with less than 0 5 phosphate dissolved into five gallons of warm water will aid in the remo
14. EROUS SPRING IMPORTANT THE SPRING WARNING TAG S SUPPLIED MUST BE SECURELY ATTACHED TO THE STATIONARY SPRING CONE IN PLAIN VIEW SHOULD A REPLACEMENT SPRING WARNING TAG BE REQUIRED CONTACT WAYNE DALTON CORP FOR FREE REPLACEMENTS CENTER BEARING BRACKET TORSION SPRING STATIONARY SPRING CONE NYLON CENTER BUSHING SPRING WARNING TAG 1 3 8 16 NUT 1 3 8 16 X 1 1 2 HEX HEAD BOLT TORSION SPRING 1 3 8 16 X 1 1 2 HEX HEAD BOLT 24 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Tools Needed Vice Grips 3 8 Wrench Tools Needed Vice Clamp To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Counterbalance Cables Release the vice grips from the ends of the cables and thread the counterbalance cables around the back side of the left cable drum and verify that there is no cable obstructions Hook the cables into the drums Slide the left hand cable drum against the left hand end bearing bracket and tighten the set screws in the drum to 14 15 ft lbs of torque Once set screws contact the tube tighten screws one full turn Rotate the left hand drum and torsion tube until cable is taut Attac
15. INSTRUCTIONS E OTHERWISE THE SPRING FITTINGS MAY s PERFORATED ANGLE RELEASE FROM SPRING IF NOT WOUND i BOLTED USING 2 5 16 IN THE PROPER DIRECTION AND COULD J X 1 5 8 HEX HEAD LAG SCREWS TO CEILING RESULT IN SEVERE OR FATAL INJURY MEMBER AND PARALLEL TO DOOR P Now lift door and check it s balance ss xD ro THE TRACK TO SERVE AS to pull down Loosen set screws before AROLLER STOP adjusting the number of turns of spring tension To adjust spring s only add S T SN or remove 1 4 turn on the springs at a x SOUND FRAMING MEMBERS _ time Adjust both sides equally Tighten 5 li Sua set screws once adjustments have been completed MA PERFORATED ANGLE BOLTED USING 2 5 16 X 1 5 8 HEX HEAD LAG SCREWS TO CEILING MEMBER AND PARALLEL TO DOOR IMPORTANT DO NOT ADD OR REMOVE MORE THAN 1 SPRING TURN FROM SPECIFIED AMOUNT IF THE DOOR STILL DOES NOT OPERATE EASILY LOWER THE DOOR TO THE CLOSED POSITION UNWIND SPRING S TO ZERO AND RECHECK THE FOLLOWING ITEMS HORIZONTAL TRACK Se gsseecpged 2000000000 00000 60000 90000 BOLT MUST EXTEND INTO THE TRACK TO SERVE AS AROLLER STOP 1 Check the door for level 2 Check the torsion spring tube and PERPUMATEU ANOLE flagangles for level and plumb 3 Check the distance between the ONV N Si WEATHER flagangles must be door width V Pie SEAL plus 3 3 8 to 3 1 2 DEA 4 Check the counterbalance cables for equal ten
16. KET BOTTOM SECTION 3 8 FLAT WASHER COUNTERBALANCE CABLE BOTTOM BRACKET b COUNTERBALANCE ASSEMBLY BOTTOM SECTION BOTTOM BRACKET BOTTOM SECTION Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com 6 Bottom Section DOOR OPENING Tools Needed Before installing the bottom section Level the weather seal may not be included must be installed see PREPARING THE OPENING on page 10 Center the bottom section in the door opening Level section using wooden shims if necessary under the bottom astragal WEATHER SEAL INSTALLATION WOODEN SHIMS IF NECESSARY F Vertical Track lt BOTTOM SECTION Tools Needed IMPORTANT THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL 546 X1 5 8 FROM SIDE TO SIDE IF THE BOTTOM n LAG SCREWS SECTION WAS SHIMMED TO LEVEL IT at THE VERTICAL TRACK ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF 7 16 Socket THE SHIM Driver qwe VERTICAL TRACK Position the left hand vertical track iK ASSEMBLY LAG assembly over the rollers of the bottom SCREW section Make sure the counterbalance LOCATIONS cable is located between the rollers and the door jamb Drill 3 16
17. MENT MANUAL MOTOR DOOR HEIGHT TRACK NET eae Re 110 137 E TS Radius 0704 mm 3480 mm Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Installation IMPORTANT READ INSTRUCTIONS TITLED P4 REMOVING THE OLD DOOR ON PAGE 9 AND P5 PREPARING THE OPENING ON PAGE 10 BEFORE ATTEMPTING DOOR INSTALLATION IMPORTANT STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS END BRACKETS JAMB BRACKETS OPERATOR MOUNTING SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER PRESERVATIVE TREATED STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN TREATED LUMBER NOTE It is recommended that 5 16 x 1 5 8 lag screws be pilot drilled using a 3 16 drill bit and 1 4 x 2 lag screws and 1 4 x 1 1 2 lag screws be pilot drilled using a 1 8 drill bit prior to fastening z 3 E E 7 QUICK INSTALL TAB UNLOCKED QUICK INSTALL TAB LOCKED Attaching Quick Install Flagangle to Vertical Track Tools Needed NOTE if you have fully adjustable None flagangle skip this step and complete Step 2 Place the lower quick install tab of the flagangle in the quick install feature of FLAGANGLE FLAGANGLE the vertical track Give
18. NG PLIERS Step 9 Lift the right hand side of the Su TorqueMaster Spring Tube and slide the Wu cable drum off Realign the groove in the winding shaft with the radial notch in the flagangle and drape the counterbalance CENTER cable with drum over the flagangle Lift BRACKET REMOVE CABLE DRUM AND the left hand side of the TorqueMaster ASSEMBLY p WINDING SHAFT Spring Tube and slide the cable drum P and winding shaft off Fig 9 Drape the counterbalance cable with drum over the flagangle Lift the TorqueMaster spring assembly off the flagangles and out of the doorway Unhook the counterbalance cables from the bottom brackets and remove all parts from the work area NOTE The cable drums may be difficult to remove If so twist the cable drum to aid in removal DRAPE CABLE LIFT aipa 2 5 16 X 1 5 8 ACROSS 4 TORQUEMASTER NOTE Continue with P4 on page 9 after HEX HEAD LAG TOP OF SPRING TUBE completing this step SCREWS FLAGANGLE OFF FLAGANGLE Fig 8 Fig 9 8 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Tools Needed Recommended tools from page 5 Tools Needed Recommended tools from page 5 To find your Wayne Dalton dealer refer to your local yellow pages business listings or
19. NGS 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 COUNTER GEAR COUNTER Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 7 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com PRE INSTALLATION TorqueMaster Spring Removal continued Tools Needed Spring Tube should be free to rotate in either direction If the counterbalance R ded cable is still taut and the TorqueMaster ecommended Spring Tube is difficult to rotate that is an tools from indicat
20. PENDING ON THE DOOR MODEL SOME PARTS Package Contents LISTED WILL NOT BE SUPPLIED IF NOT NECESSARY REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR DOOR SECTIONS AS REQUIRED 1 TORSION TUBE 2 FULLY ADJUSTABLE RH LH 2 QUICK INSTALL RH LH 2 HORIZONTAL TRACK RH LH FLAGANGLE AS REQUIRED FLAGANGLE AS REQUIRED TORSION SPRINGS 2 BOTTOM BRACKETS 1 OPERATOR BRACKET 2 TOP BRACKET AS REQUIRED AMA RIGHT amp LEFT DRUMS FULLY ADJUSTABLE JAMB DOOR STOP amp NAILS WEATHER SEAL amp NAILS 2 VERTICAL RIGHT AND LEFT Q I JAMB BRACKETS IF INCLUDED TRACK RH LH COUTNERBALANCE CABLE AS REQUIRED BRACKETS AS REQUIRED IF INCLUDED 1 CENTER BRACKET PULL ROPE MANUAL 1 CENTER BRACKET RIGHT amp LEFT ROLLERS END BEARING BRACKET AS REQUIRED BUSHING IF INCLUDED 0 0 O 2 3 8 FLAT 2 5 16 FLAT 3 8 16 HEX NUTS 1 4 20 FLANGED HEX 1 4 20 X 9 16 TRACK 4 1 4 20 X 9 16 LARGE WASHERS WASHERS AS REQUIRED NUTS AS REQUIRED BOLTS AS REQUIRED HEAD RIBBED TRACK BOLTS NV JA SZ 2 CLEVIS PINS 1 4 14 X 5 8 SELF TAPPING 2 1 4 20 X 5 8 TAMPER 1 4 20 X 5 8 SELF DRILLING 1 4 20 X 7 8 SELF DRILLING SCREWS AS REQUIRED RESISTANT SCREWS AS REQUIRED SCREWS AS REQUIRED SCREWS AS RE
21. QUIRED od 3 8 16 X 1 1 2 HEX HEAD 5 16 X 1 5 8 HEX HEAD LAG 5 16 X 2 TAMPER PROOF LAG 2 COTTER PINS SCREWS AS REQUIRED SCREWS AS REQUIRED Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com 4 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 sequence is always determined by 1 being the bottom section to 3 or 4 being the highest intermediate section See views to the right If the stamp on the end hinge is illegible refer to the section side view illustration to the right The section side view illustration shows the end hinge profile of all the sections and can also be used in conjunction with identifying each sections The BOTTOM SECTION can be identified by 1 end hinges the factory attached bottom astragal and by the bottom bracket warning labels on each end stile The LOCK SECTION can be identified by a 2 end hinge The INTERMEDIATE SECTION can be identified by 3 end
22. SECURING THE END HINGES TO THE SECTIONS WITH 1 4 14 X 5 8 SELF TAPPING SCREWS A ENSURE THEY ARE ATTACHED AS M ALIGNMENT SHOWN IN THE ILLUSTRATIONS ABOVE I STICKERS IMPORTANT PUSH amp HOLD THE HINGE LEAFS AGAINST SECTION WHILE SECURING WITH 1 4 14 X 5 8 SELF TAPPING SCREWS END HINGES HAVE 2 SCREWS AND INTERMEDIATE HINGES HAVE 3 SCREWS NOTE Install lock at this time sold separately see instructions in OPTIONAL SIDELOCK INSTALLATION on page 29 2 1 4 14 X 5 8 SELF TAPPING SCREWS END HINGES SELF TAPPING SCREWS 16 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Operator Bracket Tools Needed NOTE If installing a trolley type operator complete this step If not skip Power Ball this step and continue with step 10 7 16 Socket Driver IMPORTANT WHEN INSTALLING A Z TROLLEY TYPE OPERATOR ON 9800 f 1 4 20 X 7 8 SELF DOOR A WAYNE DALTON TROLLEY y DRILLING SCREWS BRACKET MUST BE SECURELY 2 ATTACHED TO THE TOP SECTION IT IS THEN UNNECESSARY TO FURTHER REINFORCE THE TOP SECTION OF THE MODEL 9800 WAYNE DALTON DOOR WHEN ATTACHING A TROLLEY TYPE OPERATOR AS LONG AS THE INSTALLATION OF THE OPERATOR IS ACCORDING TO INSTALLATION INSTRUCTIONS AND OWNER S MAN
23. UAL Nd AND FORCE SETTINGS ARE ADJUSTED B OPERATOR PROPERLY ed BRACKET Remove but retain 4 6 1 4 20 x 7 8 self drilling screws from the center of the u bar allowing the operator bracket to slide between the section and the u bar INSTALLATION NOTE For retro fit applications the operator bracket must be aligned with an existing operator TOP OF SECTION TOP EDGE OF Locate the center of the top section and A 1 OPERATOR slide operator bracket under u bar till eX OF BRACKET the operator bracket is seated against the u bar flange i NOTE Prior to fastening operator bracket to top section ensure the top edge of operator bracket is aligned with OPERATOR the top edge of the section as shown on BRACKET far right OPERATOR BRACKET Attach the operator bracket using 6 1 4 20 x 5 8 self drilling screws as shown Finish re attaching the u bar using the self tapping screws removed previously 0 On 6 1 4 20 X 5 8 SELF DRILLING SCREWS OPERATOR BRACKET IN PLACE UNDER U BAR Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 17 To find your Wayne Dalton dealer refer to your local yellow p
24. Wayne Dalton 9800 Series 4 Section Low Head Room Front Mount Torsion Spring Installation Instructions and Owner s Manual IMPORTANT NOTICE Wayne Dalton Corp Read these instructions carefully before P O Box 67 attempting installation If in question about Mt Hope OH 44660 any of the procedures do not perform the work Instead have a qualified door agency www wayne dalton com i do the installation or repairs Copyright 2009 Wayne Dalton Corp Part No 341785 REV1 08 03 2009 Table of Contents mponantsareiviinstiuctions ccscccoccnocsncccncomeomeeonecenecoseceanscanceen g Package Gontentss sesensseonto S TESTOR E 3 DjoongSectonildentificatiormeeeee E S 4 j oolS Bequitediees m e E EMT TEN TE EUN 5 Prezlnstalladofbe sese RETE 5 10 Tiermovingimelodiboone ME 5 9 PrepanngomiheiOpenino r e seen ree 10 Instalationt e eaa e 11 28 Optianalliistallatonsee see 29 30 Side lock ee 29 PulllRopgee eT 29 Troll Operator cere 30 Maintenance NET TEE 31 32 cleaning anA eee 31 PFET UAT YG PSU E HO TES 32 Warranty 33 Dealenitocatoninformaltioneeee MM 34 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
25. Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com 14 5 Bottom Bracket Tools Needed Power Drill 7 16 Socket Driver IMPORTANT Right and left hand is always determined from inside the garage looking out NOTE For door section identification see page 4 Locate the left hand bottom bracket Align the bracket horizontally with the top edge of the pre installed bottom bracket Also align the bracket vertically with the left edge of the bottom section Attach the bracket using 4 1 4 20 x 11 16 self drilling screws and 1 1 4 20 x 5 8 tamper proof screw as shown Uncoil the counterbalance cables Place clevis pin into the inside tab of the bracket and slide the teardrop of the counterbalance cable onto pin Continue sliding clevis pin thru the outside tab of the bracket Place a washer onto mildford pin and secure in place using a cotter pin as shown Insert a roller into the pre attached bottom bracket of the bottom section and insert another roller at 1 end hinge at the top of the bottom section Repeat for other side NOTE Verify astragal bottom seal is aligned with door section If there is more than 1 2 excess astragal on either side trim astragal even with door section 4 1 4 20 X 11 16 SELF DRILLING SCREWS 1 1 4 20 X 5 8 TAMPER PROOF SCREW a BRAC
26. a manner other than described in the immediately preceding paragraph then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy The liability of the Manufacturer whether in contract or tort under warranty product liability or otherwise will not go beyond the Manufacturer s obligation to repair or replace at its option as described above THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES including but not limited to damage or loss of other property or equipment personal injury loss of profits or revenues business or service interruptions cost of capital cost of purchase or replacement of other goods or claims of third parties for any of the foregoing 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 ri
27. ages business listings or go to Find a dealer area online at www wayne dalton com 1 0 Top Section DOOR WIDTH 3 3 8 TO 3 1 2 Tools Needed Place the top section in the opening Hammer and vertically align with lower sections Align vertical marks in the upper THE Pocket alignment sticker with the lower alignment sticker on right hand side on 7 16 Wrench the back of door ESIEPDNTER ER Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section 7 16 Socket Driver i Now flip up hinge leafs hold tight against section and fasten center hinges first and end hinges last Refer to Step 8 Position flagangle between 1 11 16 43 mm to 1 3 4 44 mm from the edge of the door Tighten the bottom lag screw Flagangles must be parallel to the door sections Repeat for opposite side IMPORTANT THE DIMENSION BETWEEN THE FLAGANGLES MUST BE DOORWIDTH PLUS 3 3 8 86MM TO 3 1 2 89 MM FOR SMOOTH SAFE ROLLER DOOR OPERATION Z SECTION For quick install track Complete the vertical track installation by securing the center jamb bracket s and tightening the other lag screws Repeat for opposite side For fully adjustable track PE Complete the vertical track installation by securing the center jamb bracket s and tightening the other lag screws l Pu
28. bs 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 FROM SAFETY CABLE IF INSTALLED REPEAT FOR OPPOSITE SIDE BOTTOM SECTION DOOR OPEN CAREFULLY REMOVE S HOOK AND COUNTREBALANCE CABLE REPEAT FOR THE OPPOSITE SIDE HORIZONTAL ANGLE HORIZONTAL TRACK Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 9 PRE INSTALLATION Preparing the Opening FAILURE TO SECURELY A WARNING ATTACH A SUITABLE MOUNTING PAD TO STRUCTURALLY SOUND FRAMING COULD CAUSE SPRINGS TO VIOLENTLY PULL MOUNTING PAD FROM WALL RESULTING IN SEVERE OR FATAL INJURY If you just removed your existing door or you are installing a new door complete all steps in PREPARING THE OPENING To ensure secure mounting of track brackets side and center bearing brackets or steel angles to new or retro fit construction it is recommended to follow the procedures outlined in DASMA Technical Data Sheets 156 161 and 164 at www dasma com 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 use
29. com and click on Publications and then Technical Data Sheets Number 156 161 and 164 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 5 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com PRE INSTALLATION Tools Needed Approved Winding Bars 3 8 Wrench 2 Vice Clamps Recommended tools from page 5 6 Torsion Spring Removal For Standard Lift A WARNING FAILURE TO USE APPROVED WINDING BARS CAN CAUSE SPRING 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 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
30. d The jambs must be plumb and the header level The jambs should extend a minimum of 14 356 mm above the top of the opening for Torsion spring applications For low headroom applications the jambs should extend to the ceiling height Minimum side prp required from the opening to the wall is 3 1 2 9 mm IMPORTANT CLOSELY INSPECT EXISTING JAMBS HEADER AND MOUNTING SURFACE ANY WOOD FOUND NOT TO BE SOUND MUST BE REPLACED For Torsion spring applications a suitable mounting surface must be firmly attached to the wall above the header at the center of the opening The mounting surface must be 2 x 6 lumber minimum Select southern yellow pine lumber Do not use lumber marked as spruce pine fur or SPF The mounting surface must be securely attached to the wall with four 4 3 8 anchors for masonry constructions or four 4 5 16 x 4 lag screws for wood construction NOTE Drill a 3 16 pilot hole in the mounting surface to avoid splitting the lumber Do not attach the mounting surface with nails Weather seal may not be included Door stop Cut the weather seal or door stop if necessary to fit header and jambs For quick install track Align the header seal with the inside edge of the header and temporarily secure it to the header with equally spaced nails Next fit the jamb seals up tight against the header seal and flush with the inside edge of the jamb Temporarily secure the jamb seals with equally spaced nails approximatel
31. e premises is sold nor does it extend benefits to any other person As a result this Limited Warranty does NOT apply to any person who purchases the product from someone other than an authorized Wayne Dalton dealer or distributor The Manufacturer will not be responsible for any damage attributable to improper storage improper installation or any alteration of the door or its components abuse damage from corrosive fumes or substances salt spray or saltwater air fire Acts of God failure to properly maintain the door or attempt to use the door its components or related products for other than its intended purpose and its customary usage This Limited Warranty does not cover ordinary wear This Limited Warranty will be voided if any holes are drilled into the door other than those specified by the Manufacturer THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON MOSS ACT NO WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY ABOVE Some States do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you Any claim under this Limited Warranty must be made in writing within the applicable warranty period to the dealer from which the product was purchased Unless the dealer is no longer in business a
32. ghts 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 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 Contact your local Wayne Dalton dealer 33 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com MAINTENANCE Thank you for your purchase www wayne dalton com Covered by one or more of the following Patents 5 408 724 5 409 051 5 419 010 5 495 640 5 522 446 5 562 141 5 566 740 5 568 672 5 718 533 6 019 269 6 089 304 6 644 378 6 374 567 6 561 256 6 527 037 6 640 872 6 672 362 6 725 898 6 843 300 6 915 573 6 951 237 7 014 386 7 036 548 7 059 380 7 121 317 7 128 123 7 134 471 7 134 472 7 219 392 7 254 868 Canadian 2 384 936 2 477 445 2 495 175 2 507 590 2 530 701 2 530 74 2 2 532 824 Other US and Foreign Patents pending 34 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com
33. go to Find a dealer area online at www wayne dalton com 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 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 jam
34. h vice grips to torsion tube and brace vice grips against jamb to keep cable taut Slide the right hand cable drum against the right hand end bearing bracket and rotate drum until cable is taunt Tighten set screws in right hand cable drum CABLE IMPORTANT CHECK EACH CABLE POSITIO MAKING SURE BOTH ARE SEATED PROPERLY ON THE CABLE DRUMS AND HAVE EQUAL CABLE TENSION Securing Door for Spring Winding Place vice clamps onto both vertical tracks just above the third Roller This is to prevent the garage door from raising while winding torsion spring s A WARNING FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY HOOKED IN DM PLACE VICE CLAMPS ABOVE 3RD ROLLER ON BOTH VERTICAL TRACKS VICE CLAMPS ATTACHED TO INNER RAIL OF TRACK Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer CABLE DRUM 25 INSTALLATION Winding Torsion Spring s Tools Needed 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
35. he opposite end bearing bracket Position the torsion tube so that equal amounts of the tube extend from each end bearing bracket Slide the red cable drum onto the left end of the torsion tube Slide the black cable drum onto the right end of the torsion tube Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer LEFT HAND CABLE DRUM NYLON CENTER BRACKET BUSHING LEFT HAND WOUND BLACK WINDING CONE LEFT HAND SIDE N TORSION TUBE CENTER BRACKET TORSION ASSEMBLY _ TORSION TUBE Se j e 4 NYLON CENTER BRACKET BUSHING RIGHT HAND CABLE DRUM BLACK RIGHT HAND WOUND RED WINDING CONE RIGHT HAND SIDE 23 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com INSTALLATION Nylon Center Bushing CENTER BEARING BRACKET Tools Needed Slide the nylon center bushing into the 1 2 Wrench stationary spring cone at the end of the spring and align the stationary spring cones with the holes in the center bearing bracket Secure the springs to the center bearing bracket with 2 3 8 16 x 1 1 2 hex head bolts STATIONARY and 2 3 8 16 nuts SPRING CONE IMPORTANT SPRINGS UNDER TENSION TORSION CAN BE DANG
36. he quick install feature in the track and turn the bracket perpendicular to the track so the mounting flange is toward the back flat leg of the track NOTE After completing this step continue with Step 5 0 96 TRACK QIJB 3 BOTTOM QIJB 7 FULLY ADJUSTABLE FLAGANGLE 1 4 20 FLANGE HEX NUTS VERTICAL TRACK LEFT SIDE SHOWN TWISTLOCK TAB QI JAMB BRACKET JAMB BRACKET SCHEDULE pooR 1ST SET 2ND SET 3RD SET JAMBBKT POSITION JAMBBKT POSITION JAMBBKT POSITION TOP QIJB 8 TOP QUICK INSTALL FEATURE TOP HOLE MIDDLE HOLE M STUD PLATE IF INCLUDED 1 4 20 X 9 16 LARGE HEAD RIBBED TRACK BOLTS RIGHT SIDE SHOWN 3RD SET HOLES 2ND SET HOLES 1ST SET HOLES Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Installing Fully Adjustable FULLY ADJUSTABLE JAMB BRACKETS Jamb Brackets Tools Needed NOTE If quick install flagangles were installed in Step 3 skip this step and continue with Step 5 If not complete this step None The bottom jamb bracket is always the shortest bracket included with your door If three jamb brackets are included
37. ing 3 5 16 x 1 5 8 lag screws as shown Repeat for the other side 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 CENTER OF indicate the center line of the door Then END BEARING measure from the center of the bearing in BRACKET 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 1 5 16 X 1 5 8 LAG SCREW bearing bracket on the horizontal line This MOUNTING will ensure the torsion tube is level between SURFACE the center and end bearing brackets Attach the center bearing bracket in this location to the mounting surface using 2 5 16 X 1 5 8 lag screws and 1 5 16 x 2 tamper resistant lag screw IMPORTANT USE THE 5 16 X 2 TAMPER RESISTANT LAG SCREW ONLY IF MOUNTING 1 5 16 X 1 5 8 LAG SCREW SURFACE MOUNTED OVER MASONRY TAMPER RESISTANT LAG SCREW MUST BE 1 5 16 X 2 ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BEARING BRACKET ee aa ERN HORIZONTAL LINE Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer LEFT HAND END BRACKET TOP SECTION
38. ion that spring tension still exists page 5 on the left hand spring Repeat Steps 1 and 2 for releasing spring tension on the left hand side REMOVE TOP Step 4 Using a flat tip screwdriver pry LAG SCREW the counter gear and counter cover from the right hand end bracket Fig 4 on previous page Discard the counter gear and counter cover On double spring USE LOCKING PLIERS applications repeat for left hand side TO HOLD END BRACKET Step 5 Remove the upper 5 16 x 1 5 8 lag screw from the right hand end bracket Fig 5 Attach locking pliers to REMOVE 10 the upper portion of the end bracket and A PHILLIPS HEAD hold the housing steady while removing NW TESS SCREW the lower 5 16 x 1 5 8 lag screw and 10 x 1 2 phillips head screw from the end bracket Fig 6 Step 6 Holding the right hand end bracket steady with locking pliers carefully pry the end bracket and drive gear off the winding shaft using a flat tip SCREW screwdriver Fig 7 CAUTION THE WINDING SHAFT MAY HOLD THE ROTATE WHEN REMOVING THE END p END BRACKET BRACKET AND DRIVE GEAR STEADY WITH Step 7 Repeat Step 4 for the left hand LOCKING PEERS side Holding the left hand end bracket steady with locking pliers carefully pry the end bracket off the winding shaft using a flat tip screwdriver Fig 7 Step 8 Remove the two 2 lag bolts 4J PRY END BRACKET FROM WINDING an tote assembly to J SHAFT USING A FLAT TIP SCREW Z DRIVER AND LOCKI
39. l with the door the middle bracket on the 1 1 4 20 X 9 16 track is the middle bracket in height TRACK BOLT The top jamb bracket is the tallest bracket included To attach the bottom jamb bracket 1 1 4 20 V FLANGE VERTICAL locate the lower hole slot pattern of HEX NUT TRACK the vertical track Align the slot in the jamb bracket with the lower hole of the JAMB BRACKET hole slot pattern in the vertical track Loosely hand fasten the bracket onto the track with 1 1 4 20 x 9 16 track bolt and 1 1 4 20 flange hex nut INSTALLATION Place the center jamb bracket over pu the hole slot pattern that is centered C between the bottom jamb bracket and flagangle Align the slot in the jamb bracket with the lower hole of the hole slot pattern Loosely hand fasten the bracket onto the track with 1 1 4 20 x 9 16 track bolt and 1 1 4 20 flange hex nut Repeat if a third jamb bracket is provided equally spacing the distance between the two center jamb brackets and the bottom jamb bracket and flagangle 3RD SET NOTE While the bottom jamb bracket is the shortest in length that is included 2ND SET with your door It does not necessarily B mean it is the short ST 0 jamb bracket 1ST SET Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 13 To find your
40. l liability for the finishing 32 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com 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
41. m floor on the right or left side of jamb Drill 1 8 pilot hole for No 6 screw eye Tie the pull rope to the No 6 screw eye and to the bottom bracket as shown PULL ROPE Q 4 1 4 20 X 11 16 SELF DRILLING SCREW D Q Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer OPTIONAL INSTALLATION 29 e Trolley Operator Tools Needed A WARNING SUITABLE OPERATOR RAIL J s OPERATOR MUST BE TESTED LUMBER MINIMUM RKA z L AT TIME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR FAILURE TO ADJUST OPERATOR IF NECESSARY CAN RESULT IN SEVERE OR FATAL INJURY IF YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED FAILURE TO MAKE ADJUSTMENTS IF NECESSARY CAN RESULT IN SEVERE OR FATAL INJURY 1 Install operator rail 1 2 to 1 13 38 mm above high arc of top section of the door 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
42. ng tension until door rests on the floor If the door is hard to raise or drifts down on its own add spring tension An C APPROVED unbalanced door such as this can REN WINDING BARS cause garage door opener operation problems 26 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Rear Support Tools Needed A WARNING Ratchet Wrench KEEP HORIZONTAL TRACK 1 2 Socket PARALLEL AND WITHIN 3 4 MAXIMUM OF DOOR EDGE 1 2 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 the horizontal track are not yet supported at the rear A WARNING RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE INJURY OR DEATH Level Hammer Tape Measure Clamp a pair of vice clamps on the vertical tracks just above the second roller on one side just below the second roller on the other side This will prevent the door from raising or lowering while installing the rear support Using perforated angle 5 16 x 1 5 8 hex head lag screws and 5 16 bolts with nuts may not be supplied fabricate rear support for horizontal tracks Attach horizontal tracks to the rear supp
43. number of complete turns to balance your door Power Drill 3 16 Drill Bit 7 16 Socket Driver u 8 0 Door Height Approx 8 3 4 Turns Phillips Head Screwdriver A WARN NG PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS ENSURE YOU RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTALLATION INSTRUCTIONS OTHERWISE THE SPRING FITTINGS MAY RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD RESULT IN SEVERE OR FATAL INJURY Alternately inserting the winding bars into the holes of the spring s winding cone rotate the winding cone upward toward ceiling 1 4 turn at a time until the required number of complete turns for your door height is achieved As the last 1 4 turn is achieved securely hold winding bar while tightening both set screws in winding cone to 14 15 ft Ibs of torque Once set screws contact the tube tighten screws one full turn Carefully remove winding bar from winding cone Repeat for the opposite spring While holding the door down to prevent it from rising unexpectedly in the event the spring s were overwound carefully remove the locking clamps from the torsion tube and the vertical tracks 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 spri
44. ompleting this step continue with Step 13 KEYSLOT I VERTICAL TRACK FLAGANGLE Al 1 1 4 20 X 9 16 N TRACK BOLT NM 1 5 16 WASHER 1 t 4 20 FLANGE HEX NUT Za A TOP CURVE OF LOW HEADROOM HORIZONTAL TRACK an Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 19 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Attaching Horizontal Track to Adjustable Flagangle Tools Needed NOTE If quick install flagangle was FLAGANGLE 7 16 Socket installed in Step 11 skip this step and continue with Step 13 If not complete Ratchet Wrench this step 7 16 Wrench 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 Flat Tip horizontal track to the flagangle with 1 stud plate and 2 1 4 20 flange hex nuts Level Screwdriver Level horizontal track and bolt the top curve of the low headroom horizontal track slot in the flagangle using 1 5 16 washer 1 1 4 20 track bolt ENDS and 1 1 4 20 flange hex nut Repeat for other side NOTE If an idrive opener will be installed position horizontal tracks slightly above level
45. orts 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 Adjust weather seal or door stop if necessary Now permanently attach the weather seal or door stop to both door jambs and header They were temporarily attached in PREPARING THE OPENING on page 10 Avoid pushing weather seal or door stop too tightly against face of door A WARNING PRIOR TO WINDING OR MAKING DOOR IN PARTIALLY OPEN POSITION N ANGE VICE CLAMPS e Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com TRACK s Il DOOR EDGE 3 4 l I I E I Tr Nd XS H HORIZONTAL F i TRACK T C2 9 z S 2 f 27 Rear Support SOUND FRAMING MEMBERS lt Tools Needed ADJUSTMENTS TO THE SPRINGS zat di T ENSURE YOU RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTALLATION
46. r door controls Severe or fatal injury could result should the child become entrapped between the door and the floor 11 Due to constant extreme spring tension DO NOT attempt any adjustment repair or alteration to any part of the door especially to springs spring brackets bottom corner brackets red colored fasteners cables or supports To avoid possible severe or fatal injury have any such work performed by a trained door systems technician using proper tools and instructions 12 On electrically operated doors pull down ropes must be removed and locks must be removed or made inoperative in the open unlocked position 13 Top section of door may need to be reinforced when attaching an electric opener Check door and or opener manufacturer s instructions 14 VISUALLY inspect door and hardware monthly for worn and or broken parts Check to ensure door operates freely 15 Test electric opener s safety features monthly following opener manufacturer s instructions 16 NEVER hang tools bicycles hoses clothing or anything else from horizontal tracks Track systems are not intended or designed to support extra weight After installation is complete fasten this manual near garage door 2 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com NOTE DE
47. sh the vertical track against the rollers so that the rollers are touching TOP the deepest part of the curved side SECTION of the track see illustration Tighten 11 16 TO 1 3 4 all track bolts and nuts Repeat for 7 opposite side FLAGANGLE 18 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com Attaching Horizontal Track to HORIZONTAL FLAGANGLE Quick Install Flagangle TRACK Tools Needed NOTE If you have fully adjustable flagangle skip this step and complete KEY SLOT 7 16 Socket Step 12 Ratchet Wrench QUICK INSTALL TAB To install horizontal track align key slot of the horizontal track with the quick install tab of the flagangle Push curved portion of horizontal track down to lock Level in place VERTICAL TRACK 7 16 Wrench Level horizontal track and bolt the top curve of the low headroom horizontal track slot in the flagangle using 1 5 16 washer 1 1 4 20 x 9 16 track bolt and 1 1 4 20 flange hex nut Repeat for other side NOTE If an idrive opener will be installed position horizontal tracks slightly above level FLAGANGLE INSTALLATION NOTE After c
48. sion adjust if necessary 3 5 16 5 Rewind the spring s BOLTS amp NUTS 6 Make sure door isn t rubbing on jambs ke 28 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com zs Tools Needed Power Drill 7 16 Socket Driver Tape Measure Tools Needed Power Drill 1 8 Drill Bit To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com 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 9 on page 17 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 fro
49. ter 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 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 SPRI
50. usting of the steel in the exposed area NOTES 1 This Limited Warranty will be voided if the original finish is painted over unless Manufacturer s preparation and painting instructions are followed explicitly 2 Consult a professional coatings contractor if in doubt about any of the above directions 3 Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers Pay particular attention to acceptable weather and temperature conditions in which to paint Fiberglass Refinishing And Or Finishing Refinishing The top coat on factory finished door may require a re coat after 1 3 years if the surface appears chalky or faded Reapply a top coat as follows Always test on a small area prior to top coating the entire door 1 Clean surfaces with soap and water mineral spirits or naptha NOTE Light scuffing of surface may be required using Scotch Brite pads 2 Apply a commercial brand of exterior grade top coat following the manufacturer instructions Finishing It is recommended that the door be purchased pre finished due to the size of the door the required spray equipment and the quality problems that could result Wayne Dalton assumes no liability for non factory finished doors If finishing is performed use exterior commercial grade finishing kits approved for use on fiberglass or commercially available exterior grade water based or oil based paint The customer assumes al
51. val of most dirt NOTES The use of detergents containing greater than 0 5 phosphate is not recommended for use in general cleaning of garage doors NOTES Be sure to clean behind weather stripping on both sides and top of door CAUTION NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH GLASS CLEANING INSTRUCTIONS Clean with a mild detergent solution same as above and a soft cloth After cleaning rinse thoroughly ACRYLIC CLEANING INSTRUCTIONS Clean acrylic glazing with nonabrasive soap or detergent and plenty of water Use your bare hands to feel and dislodge any caked on particles A soft grit free cloth sponge or chamois may be used to wipe the surface Do not use hard or rough cloths that will scratch the acrylic glazing Dry glazing with a clean damp chamois NOTE DO NOT USE any window cleaning fluids scouring compounds gritty cloths or solvent based cleaners of any kind Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer 31 To find your Wayne Dalton dealer refer to your local yellow pages business listings or go to Find a dealer area online at www wayne dalton com MAINTENANCE Steel Preparation For Painting STEEL SURFACE PREPARATION FOR PAINTING Wax on the surface must be removed or paint peeling flaking will result To remove this wax it will be necessary to lightly scuff the surface with a fine steel wool pad saturated with soapy water A final wipe and rinse should be done with
52. y 12 to 18 apart This will keep the bottom section from falling out of the opening during installation For fully adjustable track Align the header seal 1 8 to 1 4 inside the header and temporarily secure it to the header with equally spaced nails Next fit the jamb seals up tight against the header seal and 1 8 to 1 4 inside the jamb Temporarily secure the jamb seals with equally spaced nails approximately 12 to 18 apart This will keep the bottom section from falling out of the opening during installation NOTE Do not permanently attach weather seal or door stop to the jamb at this time 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 BACKROOM REQUIREMENT Backroom is defined as the distance needed from the opening back into the garage to allow the door to open fully Tools Needed Recommended tools from page 5 10 SUITABLE MOUNTING SURFACE 2 X 6 LUMBER MINIMUM HEADER BOARD 2 X 6 LUMBER PREFERRED DOOR HEIGHT LEVEL HEADER PLUMB JAMBS HEADROOM HEADER BACKROOM WEATHER SEAL WEATHER a SEAL JAMB 1 8 TO 1 4 QUICK INSTALL TRACK FULLY ADJUSTABLE TRACK DOOR DOOR STOP STOP DOOR DOOR SECTION SECTION JAMB Nue TO 1 4 HEADROOM REQUIREMENT BACKROOM REQUIRE

Wayne-Dalton 341785 User's Manual

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