Wayne-Dalton 9800 TorqueMaster Plus Garage Door Installation Instructions and Owner’s Manual

9800 doors
TorqueMaster® Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
Wayne-Dalton, a Division of
Overhead Door Corporation
P.O. Box 67, Mt. Hope, OH 44660
www.Wayne-Dalton.com
©Copyright 2010 Wayne-Dalton, a Division of Overhead Door Corporation
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. 341458 REV2 02/26/2010
Table of Contents
Important Safety Instructions................................................... 2
Package Contents.................................................................... 3
Door Section Identification....................................................... 4
Tools Required......................................................................... 5
Pre-Installation...................................................................5-10
Removing The Old Door........................................5-9
Preparing The Opening.......................................... 10
Installation . .....................................................................11-32
Optional Installations........................................................33-34
Side Lock.............................................................. 33
Pull Rope............................................................... 33
Trolley Operator..................................................... 34
Maintenance.....................................................................35-36
Cleaning................................................................ 35
Painting Instructions.............................................. 36
Warranty................................................................................ 37
Dealer Locator Information.................................................... 38
Definition of key words used in this manual:
WARNING
Indicates a potentially hazardous
situation which, if not avoided, could
result in severe or fatal injury.
CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT
FROM FAILURE TO FOLLOW INSTRUCTIONS.
IMPORTANT: Required step for safe and proper
door operation.
NOTE: Information assuring proper installation of the door.
WARNING 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. It is always recommended to wear eye protection when using tools, otherwise eye injury could result.
4.Avoid installing your new door on windy days. Door could fall during the installation causing severe or fatal injury.
5. Doors 12’ - 0” wide and over should be installed by two persons, to avoid possible injury.
6. Operate door ONLY when it is properly adjusted and free from obstructions.
7. If a door becomes hard to operate, inoperative or is damaged, immediately have necessary adjustments and/or repairs made by a trained door system technician using proper tools and instructions.
8. DO NOT stand or walk under a moving door, or permit anybody to stand or walk under an electrically operated door.
9. DO NOT place fingers or hands into open section joints when closing a door. Use lift handles/gripping points when operating door manually.
10. DO NOT permit children to operate garage door or door controls. Severe or fatal injury could result, should the child become entrapped between the door and the floor.
11. Due to constant extreme spring tension, DO NOT attempt any adjustment, repair or alteration to any part of the door, especially to springs, spring brackets, bottom corner brackets, red colored fasteners, cables or supports. To avoid possible severe or fatal injury, have any such work performed by a trained door systems technician using proper tools and instructions.
12. On electrically operated doors, pull down ropes must be removed and locks must be removed or made inoperative in the open (unlocked) position.
13. Top section of door may need to be reinforced when attaching an electric opener. Check door and/or opener manufacturer’s instructions.
14. VISUALLY inspect door and hardware monthly for worn and or broken parts. Check to ensure door operates freely.
15. Test electric opener’s safety features monthly, following opener manufacturer’s instructions.
16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks. Track systems are not intended or designed to support extra weight.
After installation is complete, fasten this manual
near garage door.
2 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
NOTE: Depending on the door model, some parts listed will not be supplied if not
necessary. Rear supports may or may not be included with your door.
Package Contents
9800 SERIES
TorqueMaster® Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
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.
© Copyright 2007 Wayne-Dalton Corp.
Part No. xxxxxx
NEW 01/03/2007
DOOR Sections (as required)
MANUAL
(1) TorqueMaster® Spring tube
(2) Horizontal Tracks RH/LH
(2) Fully Adjustable RH/LH
Flagangle (as required)
(2) Quick Install RH/LH
Flagangle (as required)
(2) Horizontal Angles
(22”, 80” or 94”)
(As required)
(1) operator bracket
(1) Center Bracket
Assembly
Rollers
(As required)
SCREW EYE AND
Pull rope
(If included)
Right & left
Drum Wraps
Right and left cable
drum assemblies
Weather seals & nails
(If included)
(2) Top Bracket Bases (2) Top Bracket Slides
r side
G
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Instr
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on
the
Door stop & nails
(If included)
(2) Vertical
Tracks RH/LH
Q.I. Jamb Brackets f.a. Jamb Brackets
(As Required)
(As Required)
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1/4” - 20 x 7/8” Self-Drilling
Screws (as required)
(4) 1/4” - 20 x 5/8”
Carriage Bolts
1/4” - 20 x 5/8” Self-Drilling
Screws (as required)
1/4” - 20 Flanged Hex
Nuts (as required)
(1) 5/16” x 1-1/4”
Clevis PIN
Stud plates
(As required)
(1) COTTER PIN
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SIDE
(1) Loose Winding Shaft 1/4” - 14 x 5/8” Self-Tapping
(SINGLE SPRING only)
Screws (as required)
VIEW
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LOWE
VIEW
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UPPE
(2) 3/8” - 16 x 3/4”
Truss Head Bolts
(2) 5/16” - 18 x 3/4”
carriage Bolts
(2) 3/8” - 16 Hex
Nuts
(2) 5/16” - 18
Hex Nuts
1/4” - 20 x 9/16” Large
head Ribbed Track BOLTS
(As required)
5/16” x 1 5/8” Hex Head Lag Screws
(as required)
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
3
Door Section Identification
Tools Needed:
Top Section
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, and #3. 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 being the highest
lock/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.
Lock Section
#3
Warning label
#1
Bottom Section
Bottom Bracket
warning Labels
Astragal
3 SECTION 7’0” high shown above
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.
Top Section
#3
Warning label
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.
Intermediate Section
#2
The lock section can be identified
by #2 end hinge.
Lock Section
NOTE: On 3 section high doors, the
lock section can be identified by
#3 end hinge and the section will have
a warning label attached to either the
right or left hand end stile.
#1
Bottom Bracket
warning Labels
Astragal
Bottom Section
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.
4 SECTION 8’0” high shown above
1 3/8”
The top section can be identified by
no pre-installed hinges on the section
and the warning label attached in the
center of the section.
#3 end
hinge
Top
int.
lock
1 1/8”
#2 end
hinge
7/8”
#1 end
hinge
Bottom
BOTTOM
BRACKET
Astragal
Typical hinge stamping location
SECTION side view shown above
4 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Power Drill
Ratchet Wrench
Pliers/Wire Cutters
Tape Measure
1/8”, 3/16” Drill Bits
Phillips Head Screwdriver
Flat Tip Screwdriver
Pencil
Needle Nose Pliers
Gloves
7/16”, 1/2”, 9/16”
Sockets
7/16” Socket Driver
3/8”, 7/16”, 1/2”, 9/16”
Wrenches
Safety Glasses
PRE-INSTALLATION
Tools Required
Step Ladder
Hammer
vice grips
Vice clamps
(2) Saw Horses
Removing An Old Door
WARNING
If your counterbalance system is other than those mentioned IN SECTIONS P1, P2 AND P3, do not
attempt to work on it, but have a qualified door agency perform the work. Otherwise, severe or
fatal injury could result.
WARNING
Disconnect and remove any electric opener prior to removal of counterbalance systems to
prevent unintended door operation. Otherwise, severe or fatal injury could result.
WARNING
Counterbalance spring tension must be relieved before removing any hardware. A powerful
spring releasing it’s energy suddenly can cause severe or fatal injury.
WARNING
If you have back problems do not attempt this, or severe injury could result
WARNING
Removing an existing door can be dangerous. Follow instructions on pages 6-10 “removing an old
door/preparing the opening” carefully, otherwise, severe or fatal injury could result.
If you have an existing door, follow the instructions to identify which counterbalance removal is necessary. The process of removing
an existing door begins by identifying it’s counterbalance system. If you are not removing an existing door, proceed to Preparing The
Opening on page 10. Generally, you will find three (3) types of counterbalance systems: Torsion spring counterbalance systems, WayneDalton® exclusive TorqueMaster® and extension Spring counterbalance systems.
For more technical information regarding the opening preparation, installation and use of your garage door and opener, you can go to
www.dasma.com and click on Publications and then Technical Data Sheets Number 156, 161 and 164.
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
5
P1
Tools Needed:
Approved
Winding Bars
3/8” Wrench
Vice Clamp
Recommended
tools from
page 5
Torsion Spring Removal
For Standard Lift
SET SCREWS
WARNING
Failure to use approved
winding bars can cause
spring energy to be released
suddenly, resulting in severe
or fatal injury.
Firmly hold winding
bar and cautiously
loosen set screws
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.
Winding cone
Do not release the torsion spring
tension unless you are 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.
WINDING CONE
TORSION ASSEMBLY
APPROVED WINDING BARs
Step 3: Once set screws are loose, slowly
and carefully lower the winding rod until it
contacts 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 contacts
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.
6 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Tools Needed:
Recommended
tools from
page 5
Loosen lock
nut 1/4 turn
Counter
gear / cover
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.
Right hand
end bracket
Place mark on end bracket
and drive gear tooth
before unwinding springs
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.
Fig. 1
End bracket
Right hand
winding bolt head
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 1/4 turn using a 7/16” wrench and
continue with step 2.
If you have a gray counter cover:
Loosen the lock nut 1/4 turn 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 = 14 turns
6’-3” Door Height = 14 1/2 turns
6’-5” Door Height = 15 turns
6’-6” Door Height = 15 turns
6’-8” Door Height = 15 1/2 turns
6’-9” Door Height = 15 1/2 turns
7’-0” Door Height = 16 turns
7’-3” Door Height = 16 1/2 turns
7’-6” Door Height = 17 turns
7’-9” Door Height = 17 1/2 turns
8’-0” Door Height = 18 turns
Electric drill
with 7/16” hex
driver (do not
use impact
gun)
Fig. 2
Right hand
cable drum
TorqueMaster®
Spring Tube
Check cable
tension
Fig. 3
Counter
gear
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
Counter
cover
Pry counter gear
and counter cover
from end bracket
using flat Tip
screwdriver
Fig. 4
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
7
PRE-INSTALLATION
P2
TorqueMaster® Spring Removal
TorqueMaster® Spring
Removal Continued...
Tools Needed:
Recommended
tools from
page 5
should be free to rotate in either direction.
If the counterbalance cable is still taut and
the TorqueMaster® Spring Tube is difficult
to rotate, that is an indication that spring
tension still exists on the left hand spring.
Repeat Steps 1 and 2 for releasing spring
tension on the left hand side.
Step 4: Using a flat tip screwdriver,
pry the counter gear and counter cover
from the right hand end bracket (Fig. 4
on previous page). Discard the counter
gear and counter cover. On double spring
applications, repeat for left hand side.
Remove top
lag screw
Fig. 5
Use locking pliers
to hold end bracket
Step 5: Remove the upper 5/16” x
1-5/8” lag screw from the right hand end
bracket (Fig. 5). Attach locking pliers to
the upper portion of the end bracket and
hold the housing steady while removing
the lower 5/16” x 1-5/8” lag screw and
#10 x 1/2” phillips head screw from the
end bracket (Fig. 6).
Step 6: Holding the right hand end
bracket steady with locking pliers,
carefully pry the end bracket and drive
gear off the winding shaft using a flat tip
screwdriver (Fig. 7).
Remove #10
Phillips head
screw
Remove
bottom lag
screw
Fig. 6
CAUTION: THE WINDING SHAFT MAY
ROTATE WHEN REMOVING THE END
BRACKET AND DRIVE GEAR.
Hold the
end bracket
steady with
locking pliers
Step 7: Repeat Step 4 for the left hand
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).
Pry end bracket from winding
shaft using a flat tip screw
driver and locking pliers
Step 8: Remove the two (2) lag bolts
attaching the center bracket assembly to
the header board (Fig. 8).
Step 9: Lift the right hand side of the
TorqueMaster® Spring Tube and slide the
cable drum off. Realign the groove in the
winding shaft with the radial notch in the
flagangle and drape the counterbalance
cable with drum over the flagangle. Lift
the left hand side of the TorqueMaster®
Spring Tube and slide the cable drum
and winding shaft off (Fig. 9). Drape the
counterbalance cable with drum over the
flagangle. Lift the TorqueMaster® spring
assembly off the flagangles and out of
the doorway. Unhook the counterbalance
cables from the bottom brackets and
remove all parts from the work area.
NOTE: The cable drums may be difficult to
remove. If so, twist the cable drum to aid
in removal.
NOTE: Continue with “P4” on page 9 after
completing this step.
Fig. 7
CENTER
BRACKET
ASSEMBLY
Remove cable drum and
winding shaft
Drape cable
(2) 5/16” x 1-5/8”
Lift
hex head lag
across
TorqueMaster®
screws
Top of flagangle Spring Tube
Off flagangle
8 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
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.
PRE-INSTALLATION
P3
Remove lag screw
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
NOTE: Continue with “P4” after completing
this step.
P4
Tools Needed:
Recommended
tools from
page 5
Removing the Old Door
Having removed the counterbalance
system, the door can now be
disassembled.
Top bracket
Horizontal track
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.
Hinges
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.
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
9
P5
Tools Needed:
Recommended
tools from
page 5
Suitable mounting surface
2” x 6” lumber minimum
Preparing the Opening
If you just removed your existing door or you are installing a
new door, complete all steps in PREPARING THE OPENING.
To ensure secure mounting of track brackets, side
and center brackets, or steel angles to new or retro-fit
construction, it is recommended to follow the procedures
outlined in DASMA Technical Data Sheets #156, #161 and
#164 at www.dasma.com.
The inside perimeter of your garage door opening should
be framed with wood jamb and header material. The jambs
and header must be securely fastened to sound framing
members. It is recommended that 2” x 6” lumber be used.
The jambs must be plumb and the header level. The jambs
should extend a minimum of 12” (305 mm) above the top of
the opening for TorqueMaster counterbalance systems. For
low headroom applications, the jambs should extend to the
ceiling height. Minimum side clearance required, from the
opening to the wall, is 3-1/2” (89 mm).
IMPORTANT: Closely inspect jambs, header and
mounting surface. Any wood found not to be sound,
must be replaced.
For TorqueMaster counterbalance systems, a suitable
mounting surface (2” x 4”) must be firmly attached to the
wall, above the header at the center of the opening.
NOTE: Drill a 3/16” pilot hole in the mounting surface to
avoid splitting the lumber. Do not attach the mounting
surface with nails.
Weather Seal (May Not Be Included):
Cut the weather seal (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 approximately 12” to 18” apart. This will keep
the bottom section from falling out of the opening during
installation.
For fully adjustable track: Align the header seal 1/8” to
1/4” inside the header and temporarily secure it to the
header with equally spaced nails. Next, fit the jamb seals
up tight against the header seal and 1/8” to 1/4” inside
the jamb. Temporarily secure the jamb seals with equally
spaced nails approximately 12” to 18” apart. This will keep
the bottom section from falling out of the opening during
installation.
NOTE: Do not permanently attach weather seal 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.
NOTE: 6” LHR Conversion Kit is available for 12” Radius only.
Contact your local Wayne-Dalton dealer.
BACKROOM REQUIREMENT: Backroom is defined as the
distance needed from the opening back into the garage to
allow the door to open fully.
Header board
2” x 6” lumber
preferred
Level header
Door
height
Plumb jambs
Door
Width
Headroom
Backroom
Header
Jamb
WEATHER SEAL
Jamb
Weather seal
Weather
seal
Weather
seal
jamb 1/8” to 1/4”
Fully adjustable Track
Door
stop
Jamb
Quick Install Track
Door
stop
Door
Section
Door
Section
Jamb
Jamb
1/8” to 1/4”
Headroom requirement
TRACK TYPE
TorqueMaster®
15” Radius track
12-1/2” (318 mm)
Backroom requirement
MOTOR
OPERATED
15” Radius 98” (2489 mm) 125” (3175 mm)
15” Radius 110” (2794 mm) 137” (3480 mm)
DOOR HEIGHT TRACK
6’6”, 7’0”
8’0”
MANUAL LIFT
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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 PT2000 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.
INSTALLATION
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.
1
Tools Needed:
None
Attaching Quick Install Flag
Angle to Vertical Track
QUICK INSTALL TAB UNLOCKED
QUICK INSTALL TAB LOCKED
NOTE: If you have fully adjustable
flagangle, skip this step and complete
Step 2.
Place the lower quick install tab of the
flagangle in the quick install feature of
the vertical track. Give the flagangle 1/4
turn to lock in place. Repeat for other
side.
FLAGANGLE
FLAGANGLE
NOTE: After completing this step,
continue with Step 3.
VERTICAL
TRACK
Left hand track and flagangle
VERTICAL
TRACK
Right hand track and flagangle
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2
Tools Needed:
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.
Fully Adjustable flagangle
1/4”- 20
flange hex
nuts
Stud plate
(IF INCLUDED)
Secure the flange nuts after flagangle
spacing is complete (Step 12).
1/4” - 20 x 9/16”
large head ribbed
Track Bolts
Vertical track
3
Tools Needed:
Hammer
Horizontal
Angle
Horizontal Angle
Position the horizontal angle as shown.
Place tabs of horizontal angle in the
key slots of horizontal track. Using
a hammer, tap the horizontal angle
towards the curved end of the track until
the holes in track and angle are aligned.
Set tracks aside.
Tabs
Hole
Key slot
Hole
Horizontal
TRACK
Horizontal
TRACK
NOTE: For larger doors, a full length
horizontal angle may be spot welded to
the horizontal track. If the horizontal angle
is not welded, the horizontal angle will be
installed as shown.
Horizontal Angle
Horizontal
TRACK
Horizontal
angle
Horizontal
TRACK
Hammer
Holes
aligned
Tabs
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Tools Needed:
None
Fully adjustable jamb brackets
NOTE: If you have quick install jamb
brackets, skip this step and complete
Step 5.
The bottom jamb bracket is always the
shortest bracket included with your
door. If three jamb brackets are included
with you door, the second bracket up
is the middle bracket in height. The
top jamb bracket is the tallest bracket
included.
To attach the bottom jamb bracket,
locate the lower hole/slot pattern of
the vertical track. Align the slot in the
jamb bracket with the lower hole of the
hole/slot pattern in the vertical track.
Secure jamb bracket, using
(1) 1/4”-20 x 9/16” track bolt and
1/4”-20 flange hex nut.
Place the center jamb bracket over
the hole/slot pattern that is centered
between the bottom jamb bracket and
flagangle. Align the slot in the jamb
bracket with the lower hole of the hole/
slot pattern. Loosely fasten the bracket
onto the track with (1) 1/4”-20 x 9/16”
track bolt and 1/4-20 flange hex nut.
ST-0
Hole / slot
pattern
Jamb
bracket
1/4”- 20 x 9/16”
Track bolt
1/4” - 20
flange hex
nut
Vertical track
Jamb bracket
Vertical
track
Repeat if a third jamb bracket is
provided, equally spacing the distance
between the two center jamb brackets
and the bottom jamb bracket and
flagangle.
NOTE: While the bottom jamb bracket
is the shortest in length that is included
with your door. It does not necessarily
mean it is the “short” (ST-0) jamb
bracket.
NOTE: After completing this step,
continue with Step 6.
ST-1
INSTALLATION
4
Installing Fully Adjustable Jamb
Brackets
3rd Set
2nd Set
1st Set
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5
Tools Needed:
Tape Measure
Installing Q.I. Jamb Brackets
NOTE: If you have fully adjustable jamb
brackets, skip this step and complete Step
6.
Measure the length of the vertical tracks.
Using the jamb bracket schedule, determine
the placement of the jamb brackets for your
door height and track type.
To install the jamb brackets, align the
twistlock tab on the quick install jamb
bracket with the quick install feature in the
track and turn the bracket perpendicular to
the track so the mounting flange is toward
the back (flat) leg of the track.
Left side shown
Twistlock
Top
tab
hole
Right side shown
3rd SET HOLES
Middle
hole
2nd SET HOLES
Q.I. jamb bracket
Bottom
hole
JAMB BRACKET SCHEDULE
DOOR
HEIGHT
6
Tools Needed:
None
1ST SET
2ND SET
3RD SET
JAMB BKT
POSITION
JAMB BKT
POSITION
6’ 6” and 7’ 0”
3 (Section High Doors)
QIJB - 3
MIDDLE
QIJB - 5
Bottom
8’ 0”
4 (Section High Doors)
QIJB - 3
MIDDLE
QIJB - 6
TOP
Drums
JAMB BKT
POSITION
Quick install feature
NOT APPLICABLE
QIJB - 7
MIDDLE
Left Hand
TORQUEMASTER®
counterbalance
DRUM
IMPORTANT: Right and left hand is
always determined from inside the
building looking out.
#1 End Hinge
(hinge tube)
NOTE: For door section identification see
page 4.
TorqueMaster® counterbalance drums
are marked right and left hand. Uncoil the
counterbalance cables and make sure you
place the right hand cable loop on the right
hand milford pin and place the left hand
cable loop on the left hand milford pin.
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.
1st SET HOLES
Counterbalance
cable
BOTTOM
SECTION
Rollers
BOTTOM
SECTION
Bottom bracket
MILFORD PIN
BOTTOM
SECTION
Astragal
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Bottom Section
Tools Needed:
Level
Before installing the bottom section,
the weather seal (may not be included)
must be temporarily installed on both
jambs and header (see Preparing the
Opening on page 10).
Weather seal
Center the bottom section in the door
opening. Level section using wooden
shims (if necessary) under the bottom
section.
Door opening
Level
TTO
BO
Wooden shims
(if necessary)
8
Tools Needed:
3/16” Drill Bit
Power Drill
7/16” Socket
Driver
Tape Measure
Level
Vertical Track
IMPORTANT: The tops of the
vertical tracks must be level
from side to side. If the bottom
section was shimmed to level it.
The vertical track on the shimmed
side, must be raised the height of
the shim.
Position the left hand vertical track
assembly over the rollers of the bottom
section. Make sure the counterbalance
cable is located between the rollers
and the door jamb. Drill 3/16” pilot
holes for the lag screws. Loosely fasten
jamb brackets and flagangle to the
jamb using 5/16” x 1-5/8” lag screws.
Tighten lag screw securing bottom
jamb bracket to jamb, to maintain
5/8” spacing. Hang cable drum over
flagangle.
CABLE
FLAGANGLE
Vertical track
5/16” x 1-5/8”
LAG SCREWS
BOTTOM SECTION
Cable
drum
VERTICAL
TRACK
ASSEMBLY
Roller
LAG
SCREW
Locations
5/8”
LAG
SCREW
Locations
15r Fully Adjustable
flagangle
JAMB
BRACKET
15r q.i. Flagangle
Quick install
jamb bracket
BOTTOM
SECTION
Repeat for the right hand side.
Lag
screw
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INSTALLATION
N
TIO
EC
MS
Power Drill
7/16” Socket
Driver
10
Tools Needed:
Power Drill
7/16” Socket
Driver
Top Brackets
NOTE: For door section identification see
page 4.
NEW 9-04-06
327985
NOTE: For door section identification see
page 4.
NOTE: Make sure hinge leafs are flipped
down, when stacking another section on top.
Place rollers in hinge tubes of the second
section (lock section). With assistance, lift
second section and guide rollers into the
vertical tracks. Align vertical marks in the
upper alignment sticker, with the lower
alignment sticker on right hand side on the
back of door. Keep sections aligned and
fasten hinges to connect the sections using
1/4” - 14 x 5/8” self-tapping screws. Repeat
for other section(s) except top section.
IMPORTANT: When securing the end
hinges to the sections with 1/4” - 14
x 5/8” self-tapping screws, ensure
they are attached as shown in the
illustrations above.
IMPORTANT: Push & hold the hinge
leafs against section while securing
with 1/4” - 14 x 5/8” self-tapping
screws. End Hinges have (2) screws
and Intermediate hinges have (3)
screws.
N
TIO
EC
KS
C
LO
Left end hinge
(3) 1/4” - 14 X 5/8”
SELF-TAPPING SCREWS
Intermediate hinge
(2) 1/4” - 14 X 5/8”
SELF-TAPPING SCREWS
(3) 1/4” - 14 X 5/8” SELF-TAPPING
SCREWS
End hinges (left hand shown, right
hinge symmetrically opposite)
Intermediate hinges
2nd set of holes
from bottom
Top section
Endcap
To install the L-shaped top brackets,
align the top holes in the top bracket
base with the second set of holes from
bottom of endcap.
Fasten top bracket base to endcap 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 bracket
will be tightened and adjusted in Step
15. Insert rollers into top bracket slide.
Alignment stickers
Right end hinge
(2) 1/4” - 14 X 5/8”
SELF-TAPPING SCREWS
NEW 9-04-06
Tools Needed:
Stacking Sections
327985
9
(2) 1/4” - 14 X 5/8”
SELF-TAPPING SCREWS
TOP BRACKET BASE
TOP
SECTION
2nd set of
holes from
bottom
(2) 1/4” - 20 x 5/8”
CARRIAGE BOLTS
TOP
TOP BRACKET
SLIDE SECTION
Repeat for other side.
(4) 1/4” - 14 x 5/8”
SELF TAPPING
SCREWS
TOP BRACKET
SLIDE
ROLLER
(2) 1/4” - 20
FLANGED
HEX NUTS
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Tools Needed:
Power Drill
7/16” Socket
Driver
NOTE: If installing a trolley type
operator, complete this step. If not, skip
this step and continue with Step 12.
IMPORTANT: WHEN CONNECTING A
TROLLEY TYPE GARAGE DOOR OPENER
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
FORCE SETTINGS MUST BE ADJUSTED
PROPERLY.
Remove, but retain (4 - 6) 1/4” - 20 x
7/8” self-drilling screws from the center
of the u-bar, allowing the operator
bracket to slide between the top section
and the u-bar.
Side view of u-bar on top
section
Top section
1/4” - 20 X 7/8”
Self-DRILLING screws
Top section
Operator
bracket
U-bar
NOTE: For retro fit applications, the
operator bracket must be aligned with
an existing operator
Locate the center of the top section and
slide operator bracket under u-bar till
the operator bracket is seated against
the u-bar flange. 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 selftapping screws removed previously.
Top section
Operator
bracket
U-bar
Operator bracket in
place under u-bar
(6) 1/4” - 20 X 5/8”
self-drilling
screws
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INSTALLATION
11
U-bar
Operator Bracket
12
Tools Needed:
Hammer
Top Section
NAIL
Door width
+3-3/8” to 3-1/2”
Place the top section in the opening and
vertically align with lower sections. Align
vertical marks in the upper alignment
sticker, with the lower alignment sticker
on right hand side on the back of door.
Temporarily secure the top section by
driving a nail in the header near the
center of the door and bending it over
the top section.
Now, flip up hinge leafs, hold them tight
against section and fasten center hinges
first and end hinges last. (Refer to Step
9).
When installing a door with a
TorqueMaster® 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. Flagangles must be
parallel to the door sections. Now,
complete the vertical track installation
by securing the center jamb bracket and
tightening the other lag screws.
327985
NEW 9-04-06
Alignment stickers
Right end hinge side
1-11/16” TO 1-3/4”
Repeat for other side.
IMPORTANT: The dimension between
the flagangles must be doorwidth plus 3-3/8” (86 mm) to 3-1/2”
(89 mm) for smooth, safe door
operation.
FLAGANGLE
Top
SECTION
327985
For fully adjustable track:
Complete the vertical track installation
by securing the center jamb bracket(s)
and tightening the other lag screws.
Push the vertical track against the
rollers so that the rollers are touching
the deepest part of the curved side of
the track (see illustration); tighten all the
track bolts and nuts. Repeat for opposite
side.
NEW 9-04-06
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.
Vertical track
ROLLER
ROLLER Against
VERTICAL TRACK
Fully adjustable
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9/16” Socket
Ratchet Wrench
9/16” Wrench
Level
Key
slot
NOTE: If you have fully adjustable
flagangle, skip this step and complete
Step 14.
Horizontal
track
To install horizontal track, place the
curved end over the top roller. Align
key slot of the horizontal track with the
quick install tab of the flagangle. Push
curved portion of horizontal track down
to lock in place. Level the horizontal
track assembly and bolt the horizontal
angle to the slot in the flagangle using
(1) 3/8” - 16 x 3/4” truss 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 12.
QUICK
INSTALL
TAB
Vertical
track
IMPORTANT: Failure to remove nail
before attempting to raise door
could cause permanent damage
to top section.
Horizontal
track
Key slot
WARNING
DO NOT RAISE DOOR UNTIL
HORIZONTAL TRACKS ARE SE­CURED
AT REAR, AS OUTLINED IN Step 26, OR
DOOR COULD FALL FROM OVERHEAD
POSI­TION CAUSING SEVERE OR FATAL
INJURY.
Flagangle
QUICK
INSTALL
TAB
Vertical
track
3/8” - 16 X 3/4”
TRUSS HEAD BOLT
3/8” - 16 Hex nut
NOTE: If an idrive® opener will be
installed, position horizontal tracks
slightly above level.
Horizontal ANGLE
HORIZONTAL TRACK
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INSTALLATION
Tools Needed:
Flagangle
13
Attaching Horizontal Track
to Quick Install Flagangle
14
Tools Needed:
7/16” Socket
9/16” Socket
Ratchet Wrench
9/16” Wrench
Level
Flat Tip
Screwdriver
15
Tools Needed:
7/16” Wrench
Attaching Horizontal Track
to Adjustable Flagangle
NOTE: If quick install flagangles were
installed in Step 13, skip this step and
continue with Step 15. If not, complete this
step.
To install horizontal track, place the curved
end over the top roller. Align the bottom of
the horizontal track with the vertical track.
Hand tighten the horizontal track to the
flagangle with (1) stud plate and (2) 1/4” - 20 flange hex nuts.
Stud
plate
Flagangle
1/4” - 20
flange hex
nuts
WARNING
DO NOT RAISE DOOR UNTIL HORIZONTAL
TRACKS ARE SE­CURED AT REAR, AS
OUTLINED IN STEP 26, OR DOOR COULD
FALL FROM OVERHEAD POSI­TION CAUSING
SEVERE OR FATAL INJURY.
Level the horizontal track assembly and
bolt the horizontal angle to the slot in the
flagangle using (1) 3/8” - 16 x 3/4” truss
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 12.
IMPORTANT: Failure to remove nail
before attempting to raise door
could cause permanent damage to
top section.
NOTE: If an idrive® opener will be installed,
position horizontal tracks slightly above
level.
3/8” - 16 X 3/4”
TRUSS HEAD BOLT
3/8” - 16 Hex nut
Horizontal ANGLE
HORIZONTAL
TRACK
Adjusting Top Brackets
With horizontal tracks installed, you can
now adjust the top brackets.
Top
section
Top
section
Vertically align the top section of the
door with the lower sections. Once
aligned, position 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 roller slide to the top
bracket base.
Incorrect
Correct
HORIZONTAL
track
TOP BRACKET
SLIDE
Top
SECTION
(2) 1/4” - 20
FLANGED HEX
NUTS
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TorqueMaster® Spring Tube
Tools Needed:
None
TorqueMaster® springs come lubricated
and pre-assembled inside the
TorqueMaster® spring tube. To install, lay
the TorqueMaster® spring tube on the
floor (inside garage) in front of the door
with the labeled end to the left.
INSTALLATION
TorqueMaster®
Spring Tube
LABELED END
17
Tools Needed:
None
Center Bracket Bushing
NOTE: If you are installing the idrive®
opener with your garage door, skip this
step and go to your idrive® Installation
Instruction/Owner’s Manual. After
completing Steps 1 thru 10 in your
idrive® Installation Instruction/Owner’s
Manual, continue with Step 22 of the
door Installation Instruction/Owner’s
Manual.
NOTE: If you are not installing an idrive®
opener with your garage door, you
must install the center bracket bushing
assembly. Continue to follow these
instructions for non-idrive® operated
garage doors.
Being cam shaped the center bracket
bushing only fits one way.
Slide the center bracket assembly
towards the center of the TorqueMaster®
spring tube, from the right side as
shown.
CENTER
BRACKET
ASSEMBLY
TorqueMaster®
Spring Tube
TorqueMaster®
Spring Tube
CENTER
BRACKET
BUSHING
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18
Tools Needed:
None
Right Hand Drum Wrap
Drum Wraps
NOTE: Drum wraps must be installed
prior to installing the TorqueMaster®
plus end bracket. Drum wrap installation
after the end bracket is installed, is not
possible without un-installing the end
bracket and it’s components.
Left Hand Drum Wrap
IMPORTANT: RIGHT AND LEFT HAND IS
ALWAYS DETERMINED FROM INSIDE THE
GARAGE LOOKING OUT.
Drum wraps are identified as right and
left. Slide the left hand drum wrap over
the left side of the TorqueMaster® spring
tube assembly with the tabs facing left.
Continue sliding the left hand drum wrap
towards the center of the TorqueMaster®
spring tube assembly. Slide the right
hand drum wrap over the right side of
the TorqueMaster® spring tube assembly
with the tabs facing right. Continue
sliding the right hand drum wrap
towards the center of the TorqueMaster®
spring tube assembly.
19
Tools Needed:
Tape Measure
Cable Drums
Shake the TorqueMaster® spring tube
assembly gently to extend the winding
shafts out about 5" on each side. For
single spring applications, there will be
no left hand spring in the TorqueMaster®
spring tube assembly.
Lift the TorqueMaster® spring tube
assembly and rest it on the top of the
flagangles.
Left Hand Drum Wrap
TorqueMaster®
Spring Tube Assembly
Tabs
TorqueMaster®
Spring Tube Assembly
Winding
Shaft
5”
NOTE: Cable drums are marked right
and left hand. Cable drums and
TorqueMaster® spring tube assembly
are cam shaped to fit together only one
way.
Right Drum
IMPORTANT: RIGHT AND LEFT HAND IS
ALWAYS DETERMINED FROM INSIDE THE
GARAGE LOOKING OUT.
To install the cable drum, slide the
correct cable drum over the winding
shaft until the cable drum seats against
the TorqueMaster® spring tube
assembly.
TorqueMaster®
Spring Tube Assembly
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Cable Drums Continued...
Tools Needed:
Groove
Splines
Winding shaft
The winding shaft must extend past the
cable drum far enough to expose the
splines and the groove. Align the winding
shaft groove with the round notch in the
flagangle.
Cable
Drum
Round Notch
For double spring applications:
Repeat for opposite side.
Flagangle
For single spring applications: Insert
the loose winding shaft into the left
hand cable drum prior to sliding the
cable drum over the TorqueMaster®
spring tube assembly.
Winding shaft
Cable
Drum
INSTALLATION
NOTE: On single spring applications,
take care in handling the loose winding
shaft (left side) so that it does not slide
back into the TorqueMaster® spring tube
assembly.
Counterbalance Cable
Groove
Splines
Loose Winding Shaft
20
Tools Needed:
Power Drill
7/16” Socket
Driver
9/16” Wrench
End Brackets
Splines
Disconnect
Cable Guide
Hole
Winding
Shaft
IMPORTANT: Warning Tags must be
securely attached to both End
Brackets.
Groove
End brackets are right and left hand. You
can identify the right hand end bracket
by the disconnect cable guide hole in
the top of the bracket.
Beginning with either side, slide the end
bracket onto the winding shaft so that
the grooves in the ratchet wheel fit onto
the winding shaft splines.
Warning
Tag
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tall llow rea d sp
rin
ati the d
g(s
on
DO
)
ins direc
truRa tion
NO
Cable
s in
T R man ctchtietoPa
Drum
EM ual. nwls/o the
wn
No
OV
spac
ers
ET
Ratch e betw
et Pa een
HIS No spac
Cable wl an
TAPawl e betwee
Drum d
G an n Ra
ind . d
DISE
NG
DISE
NG
AG
ED
AG
ED
SIDE
icates Cable tchet
enga Drum
geme
nt
VIEW
UN
DERN
EATH
VIEW
Ratch
et Pa
No
Cable
wl
spac
Ratch e betw
et Pa een
UPPE
wl an
R PO Cable
d
SITIO Drum
N
Drum
Spac
LOW
e be
twee
n Ra
an
tch
non- d Ca
indica ble Dr et Pawl
um
tes
enga
geme
nt
ER
PO
SITIO
N
Ratch
et Pa
wl in
Uppe
r
Posit
ion
UPPE
Ratch
R PO
et Pa
SITIO
N SI
DE
wl in
VIEW
LOW
ER
Lowe
r
Posit
ion
PO
SITIO
N SI
DE
VIEW
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local 23
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
End Brackets Continued...
Tools Needed:
First secure end bracket to the flagangle
using (1) 5/16” - 18 x 3/4” carriage bolt
and (1) 5/16” - 18 hex nut. Now, secure
end bracket to the jamb using (1) 5/16”
x 1-5/8” hex head lag screw. Repeat for
left hand end bracket.
Right End
Bracket
Warning Tag
Use
this these
lab Illustr
el.
ation,
WA
RN
in con
jun
Teeth Pointing
Upward
ction
Ra
wit
ch
h the
EX et Br
Ins
tru
ac
TR
ctions
ke
ENG
EM
AGE
t is
To
on
DE
the
E VIE unde
fataavoidTENSSIDSP
oth
RI
W
er sid
fast l inju poss ION. NG r
e of
en ry,
ib
er
DO le se
un s fro
til sp m NOT vere
rin ratche rem or
To
ENG
g(
AGE
sa wn s) ar t br ove
D UND
fely wo
ac
e
ERN
un
an EAT
fully ket
d H VIE unwi d.
nd
inst follo
W
alla w th read sprin
tio
g(s)
n ine dire
DO
ctio
st
NO
ns
cthet
manruRatc
Cab
T RE
ioPaw
le
in
Dru
ua ns
m
MO l. l /ownthe
No
spa
VE
ers
Ratc ce betw
TH
het
een
Paw
IS No space
Cab
l
TAPaw between
le Dru and
Gl and Cab Ratc
m
indi .
ING
DIS
ENG
AGE
het
s eng le Drum
age
men
t
cate
D SID
E VIE
W
NOTE: Ensure the 5/16” - 18 x 3/4”
carriage bolt is going through the
flagangle first, and the 5/16” - 18 hex
nut is on the outside of the end bracket.
DIS
ENG
Ratchet
Wheel
AGE
D UND
ERN
EAT
H VIE
W
Ratc
het
ER
Paw
Cab
l
No
UPP
spa
Ratc ce betw
het
een
Paw
Cab
l
le Dru and
ITIO
m
N
le Dru
m
Spa
ce
POS
betw
een
and
Ratc
Cab
het
-ind
le Dru Paw
icat
l
es eng m
age
men
t
non
LOW
ER
POS
ITIO
N
Ratc
het
Paw
l in
Upp
er Pos
ition
UPP
ER
Ratc
het
POS
ITIO
Paw
l in
N SID
E VIE
Low
er Pos
ition
W
Right End
Bracket
IMPORTANT: If ratchet gear slips
out of end bracket, ensure the
teeth on ratchet wheel are
pointing upward in a clockwise
position when sliding it back
inside the end bracket.
5/16” x 1-5/8”
Hex Head Lag
LOW
ER
POS
ITIO
N SID
E VIE
W
Use
thes
this
e
labe Illustrati
l.
on,
WA
RN
in conj
unct
ion
ENGA
5/16” - 18 x 3/4”
CARRIAGE Bolt
AND HEX NUT
DISEN
DISEN
ING
Ra
che
the
Instr
uctio
EX t Bracke
TR
ns on
ENGA
EM
the
GEDE t is
othe
und
To
SP
r side
avo TE SIDE
VIEW
fata id NSIONRINGer
of
pos
fas l injury, sib .
ten
ers DO le sev
unt from NOT ere or
il spr rat
rem
ing chet
ove
(s)
To
saf wnwo are bracke
ely
full
UNDE
y t
unwund.
RNEA
and
TH VIEW
ind
ins follow rea spring
d
tall
(s)
atio the dire
n ins
ctio
DO
Cable
tructio
ns
Drum
NO
ma Ratch
et
ns/ in the
T RE
nua Pawl
ow
MO l.
ner
No space
s
VE
No space
TH
Ratch betwe
IS TAPawl
betwe
et Pawl en
and
Cable
G.and en Ratchet
indica Cable
Drum
GED
with
GAGE
D SIDE
tes engag Drum
emen
t
VIEW
GAGE
D UNDE
RNEA
TH VIEW
Ratch
Cable
et Pawl
No space
Ratch betwe
et Pawl en
and
Cable
R POSIT
Drum
ION
Drum
Space
betwe
en Ratch
and
et Pawl
non-in Cable
dicate Drum
s engag
emen
t
UPPE
LOWE
R POSIT
ION
Ratch
et Pawl
in Upper
Positio
n
Ratch
et Pawl
UPPE
R POSIT
ION
SIDE
in Lower
VIEW
Positio
n
LOWE
R POSIT
21
Tools Needed:
Power Drill
3/16” Drill Bit
7/16” Socket
Driver
Securing Center Bracket
Assembly
NOTE: If you are installing the idrive®
opener with your garage door, skip this
step.
ION
SIDE
VIEW
CENTER
BRACKET
bushing
ASSEMBLY
NOTE: If you are not installing the
idrive® opener on your garage door, you
must install the center bracket bushing
assembly. Follow these instructions for
non-idrive® operated garage doors.
To locate the center bracket, mark the
header halfway between the flagangles
and level the TorqueMaster® spring tube.
Drill 3/16” pilot holes into header for the
lag screws. Fasten the metal bracket to
the header using (2) 5/16” x 1-5/8” lag
screws.
(2) 5/16” x 1-5/8”
hex head lag
screws
24 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Tools Needed:
Vice Clamps
Place vice clamps onto both vertical
tracks just above the third roller. This is
to prevent the garage door from raising
while winding counterbalance springs.
WARNING
NOTE: Four section, 8’0” high
door is shown.
Failure to place vice clamps
onto vertical Track can
allow door to raise and
cause severe or fatal
injury.
Place vice
clamps above
3rd Roller
Vice clamps
attached to
track
23
Tools Needed:
Pliers/Wire
Cutters
Flat Tip
Screwdriver
Cable Adjustment
Track
INSTALLATION
22
Securing Door
for Spring Winding
First Groove
Starting on the right side, adjust the
cable drum assembly by rotating the
drum until the set screw faces directly
away from the header. Loosen the set
screw no more than 1/2 turn.
Pull on the end of the cable to remove
all cable slack. Check to ensure the
cable is aligned and seated in the first
groove of the cable drum. Snug the set
screw, and then tighten an additional
1-1/2 turns.
Cut off excess cable.
Set Screw
WARNING
Use these Illustration, in conjunction with the Instructions on the other side of
this label.
Rachet Bracket is under
EXTREME
SPRING
ENGAGED SIDE
VIEW
TENSION.
To avoid possible severe or
fatal injury, DO NOT remove
fasteners from ratchet bracket
until spring(s) are fully
wnwound.
To safely unwind spring(s)
Cable Drum
read
ENGAGED UNDERNEATH VIEW
and follow the directions in the
installation instructions/o
Ratchet Pawl wners
manual.
No space between Ratchet
Pawl and Cable Drum
DO NOT REMOVE THIS TAG.
Counterbalance Cable
in First Groove
Cam Peak Strait Up
IMPORTANT: Ensure the cable is
aligned and seated in the First
groove of the cable drum prior to
winding springs.
indicates engagement
No space between
Ratchet Pawl and
Cable Drum
DISENGAGED SIDE VIEW
Cable Drum
DISENGAGED UNDERNEATH VIEW
Ratchet Pawl
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
No space between
NOTE: Illustrations show the right
TorqueMaster® Plus drum, left
TorqueMaster® Plus drum is
symmetrically opposite.
Ratchet Pawl and
Pliers
Set Screw
Counterbalance
Cable
Cable Drum
UPPER POSITION
LOWER POSITION
WARNING
Use these Illustration, in conjunction with the Instructions on the other side of
this label.
Ratchet Pawl in Upper Position
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local 25
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
UPPER POSITION SIDE VIEW
Rachet Bracket is under
EXTREME
ENGAGED SIDE
VIEW
SPRING
TENSION.
To avoid possible severe or
fatal injury, DO NOT remove
fasteners from ratchet bracket
until spring(s) are fully
wnwound.
To safely unwind spring(s)
Cable Drum
Ratchet Pawl in Lower
readPosition
ENGAGED UNDERNEATH VIEW
and follow the directions in the
installation instructions/owner
Ratchet Pawl
s
manual.
No space between Ratchet
Pawl and Cable Drum
DO NOT REMOVE THIS TAG.
indicates engagement
No space between
Ratchet Pawl and
LOWER POSITION
CableSIDE
Drum VIEW
DISENGAGED SIDE VIEW
Cable Drum
DISENGAGED UNDERNEATH VIEW
Ratchet Pawl
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
No space between
Ratchet Pawl and
24
Tools Needed:
Ratchet
5/8” Socket
3” Extension
Gloves
Winding Springs
Ratchet
WARNING
5/8” Socket
It is recommended that leather
gloves be worn while winding
the TorqueMaster® Plus springs.
Failure to wear gloves may cause
injury to hands.
3”
Extension
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.
Double check to ensure the
counterbalance cable is aligned in the
first groove of the cable drum Step 28.
Starting with the right hand side, place
a mark on winding shaft (or socket) and
end bracket.
Turn the pawl knob on the end bracket
to the upper position. Using a ratchet
wrench with a 5/8“ socket (NOTE: A
3” extension is also recommended for
added clearance from the horizontal
angle.), wind the spring by rotating the
winding shaft counter clockwise, while
watching the mark on the winding
shaft.
IMPORTANT: pawl knob must be
in upper position to add/ remove
required number of spring turns.
After 2-3 turns, remove the ratchet
wrench and adjust the cable on the left
side (step 28). Ensure the cables are in
the first groove and the cable drums, as
shown in Step 28.
NOTE: Single spring application require
no spring winding on the left hand side,
but need cable tension adjustments.
IMPORTANT: Counterbalance
cable tension must be equal on
both sides prior to fully winding
springs.
See the Spring Turn chart for
the required number of turns:
For single spring applications:
Return to the right hand and continue
winding the spring to the required
number of turns for your door. Place
pawl knob in lower position.
For double spring applications:
Place a mark on the winding shaft and
end bracket. Place the ratchet with 5/8”
socket onto the left hand winding shaft
end.
End Bracket
Use
this these
lab Illustr
el.
at
ion
Marks
RECOMMENDED SPRING TURNS
, in
WA
R
conju
nc
NIN
tion
Ra
with
ch
EX et Bra the Instr
TR
uctio
cke
ENE
GAM
ns
To
GED
on
E t is u
the
nd
fataavoidTENSSIDSE P
othe
VIE
R
e
W
r sid
fast l inju poss ION ING r
e of
.
en ry,
ers DOible se
un
fro
til sp
m NOT vere
ra
o
re
rin
m r
To
ENGA
g tch
sa wn (s) a et b ove
GED
rack
fely wo
UN
re
DE
u
anRNEA
fully et
d TH VIE unwinnd.
inst follo
W
d
re
sp
alla w th ad
rin
tio e d
g(s
n in ire
DO
)
stru ctio
NO
Rat
ns
Cable
T R man ctcheiot Paw
in
Dru
EM ual. ns/l o the
m
wn
No
OV
spa
ers
ET
Rat ce bet
che
we
HIS No spa
t Paw en
Cable l and
TAPaw ce betwe
Dru
Gl and Ca en Rat
m
ind .
G
icates
DIS
ENGA
GED
SID
E VIE
che
ble
t
eng Drum
age
me
nt
W
Door Height
Spring Turns
6’-6”
15
DIS
ENGA
GED
UN
DERN
EATH
VIE
W
Rat
No
spa
Rat ce bet
che
t Paw
che
t Paw
l
Cable
Dru
m
ween
R PO Cable l and
Dru
SIT
ION m
UPPE
Spa
ce
bet
we
and en Rat
che
Ca
t Paw
-indic ble
l
ate Drum
s eng
age
me
nt
non
LOWE
R PO
7’-0”
8’-0”
SIT
ION
16
18
Rat
che
t Paw
l in
Upper
Pos
ition
UPPE
R PO
Rat
che
t Paw
l in
SIT
ION
SID
E VIE
Low
er Pos
ition
W
LOWE
R PO
SIT
ION
SID
E VIE
W
End Bracket
Pawl Knob in Upper
Position
End Bracket
Pawl Knob in Lower
Position
26 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Back of torquemaster® plus end bracket warning tag(s)
Winding Springs Continued...
25
Tools Needed:
None
To wind the spring, rotate the winding shaft
clockwise, while watching the mark on the
winding shaft. Rotate the winding shaft to
the required number of turns for your door.
Then return to the right hand side and
wind the right hand spring to the required
number of turns. Place pawl knob in lower
position on both sides.
IMPORTANT: Mark number of spring
turns on TorqueMaster® Plus end bracket
warning tag(s).
NOTE: Since total turns to balance door
can deviate from spring turn chart
values by ± 1/2 turn, adjustments to the
recommended number of turns may be
required after rear hangers assembly is
completed.
IMPORTANT! Hold the door down to
prevent it from rising unexpectedly
in the event the spring was
overwound and cautiously remove
vice clamps from vertical tracks.
IMPORTANT! Adjustments to the
recommended number of turns may
be required. If door raises off the
floor under spring tension alone,
then reduce spring tension until
door rest on the floor. If the door
is hard to raise or drifts down on
its own, then add spring tension.
Spring Turns
Door Height
14
(6’ - 3”)
14 - 1/2
(6’ - 5”)
15
(6’ - 6”)
15
(6’ - 8”)
15 - 1/2
(6’ - 9”)
15 - 1/2
(7’ - 0”)
16
(7’ - 3”)
16 - 1/2
(7’ - 6”)
17
(7’ - 9”)
17 - 1/2
(8’ - 0”)
18
Location for
marking number
of installed
spring turns
Number of Installed Spring Turns
Drum wrap
(left hand)
Drum Wrap Installation
To install drum wraps, position the left
hand drum wrap over the left hand
drum, align with counterbalance cable;
slide groove in drum wrap towards the
left until tabs snap over drum in
between drum and ratchet gear. Repeat
for right hand side.
Spring Turns
(6’ - 0”)
INSTALLATION
Tools Needed:
Drum
(left hand)
IMPORTANT: Right and Left hand
are always determined from inside
the Garage looking out.
Counterbalance
cable
Tabs
Groove
in drum
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local 27
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
26
Tools Needed:
Ratchet Wrench
1/2” Socket
1/2” Wrench
(2) Vice Clamps
Tape Measure
Level
Hammer
Rear Support
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. Do not space the
track more than 3/4” from door edge.
DOOR IN THE
UP POSITION
WARNING
Raising door further can
result in door falling and
cause severe OR FATAL INJURY.
Vice
clamps
WARNING
Keep horizontal track
parallel and within 3/4”
maximum of door edge,
otherwise door could fall,
resulting in severe OR FATAL
INJURY.
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. Fabricate rear support for
horizontal tracks, using perforated
angle, 5/16” x 1-5/8” hex head lag
screws and 5/16” bolts with nuts (may
not be supplied). 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.
IMPORTANT: IT IS NOT RECOMMENDED
THAT ANY PART OF THE HORIZONTAL
TRACK HANGER THAT CANTILEVERS 4”
BEYOND A SOUND FRAMING MEMBERS
BE USED TO SUPPORT THE WEIGHT OF
THE DOOR.
NOTE: If perforated angle is installed
over drywall, use 5/16” x 2” hex head
lag screws.
Adjust weather seal or door stop (if
necessary) and now permanently attach
the weather seal or door stop to both
door jambs and header. (They were
temporarily attached to the jambs in
PREPARING The OPENING on page 10.)
Avoid pushing weather seal or door stop
too tightly against face of door.
3/4”
HORIZONTAL
TRACK
DOOR EDGE
Vertical
TRACK
Weather seal
Weather
seal
Weather
seal
Jamb
Quick Install Track
Door
stop
Jamb 1/8” to 1/4”
Fully adjustable Track
Door
stop
Door
Section
Door
Section
Jamb
Jamb
1/8” to 1/4”
PERFORATED
ANGLE
(3) 5/16”
NUTS
(3) 5/16”
BOLTS
28 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Tools Needed:
NOTE: If an idrive® opener is installed,
position horizontal tracks one hole above
level when securing it to rear supports.
Angle
NOTE: Perforated angle must be attached
to sound framing members and nails
Horizontal
should not be used.
track
Now, lift door and check it’s balance.
Adjust, if door lifts by itself (hard to pull
Vertical
down) or if door is difficult to lift (easy to
pull down). Anytime spring adjustments
Angle
Bolt must extend into the track
are made, ratchet pawl knob must be in
to serve as a roller stop
the upper position to add/remove required
number of spring turns (refer to step 29).
To adjust springs, only add or remove a
Sound Framing Members
maximum of 3/10 of a turn (three teeth of
ratchet wheel) at a time. Both sides need to
be adjusted equally on double spring doors.
Perforated
Add Spring Tension: The ratchet wheel is
made of 10 teeth. To add spring tension,
ANGLE
ensure the ratchet and socket is set so that
it will tighten counter clockwise on the right
Perforated ANGLE - BOLTED
hand side, and clockwise on the left hand
USING (2) 5/16” X 1-5/8” HEX HEAD
side. Place the ratchet with 5/8” socket
onto the winding shaft, pull down to add
LAG SCREWS TO CEILING MEMBER
3/10 of a turn. Watch as three teeth of the
AND PARALLEL TO WIDTH OF DOOR.
24”
ratchet wheel pass over the pawl, creating
Space lag screws no further
three “clicks”.
than 24” apart.
Remove Spring Tension: To remove spring
tension, ensure the ratchet and socket is
set so that it will tighten counter clockwise
BOLT MUST EXTEND INTO THE TRACK
HORIZONTAL
on the right hand side and clockwise on
TO SERVE AS A ROLLER STOP
TRACK
the left hand side. It is recommended that
a regular 5/8” wrench be used. Place the
Sound Framing Members
wrench onto the winding shaft. Pull down
on the wrench to relieve pressure between
PERFORATED ANGLE
the pawl and the ratchet wheel. Push in on
the pawl to allow the three ratchet wheel
teeth to pass by the pawl, as you carefully
Perforated ANGLE -BOLTED USING
allow the wrench to be rotated upward by
(2) 5/16” X 1-5/8” HEX HEAD LAG
the spring tension. Release the pawl to
SCREWS TO CEILING Members
allow it to engage with the ratchet wheel.
Important: BE PREPARED TO HOLD THE
AND PARALLEL TO WIDTH OF DOOR.
FULL TENSION OF THE SPRING.
Attach vertical perforated angle
Important: DO NOT ADD OR REMOVE
between the (2) 5/16” X 1-5/8”
MORE THAN 1 SPRING TURNS (1 SPRING
HEX HEAD LAG SCREWS, securing
TURN EQUALS 10 TEETH ON RATCHET
perforated angle to ceiling
WHEEL) FROM THE RECOMMENDED
members.
NUMBER OF TURNS SHOWN ON THE
HORIZONTAL
SPRING TURN CHART.
BOLT MUST EXTEND INTO THE TRACK
If the door still does not operate easily,
TRACK
TO SERVE AS A ROLLER STOP
lower the door into the closed position,
UNWIND SPRING(S) COMPLETELY, and
recheck the following items:
1.) Check the door for level.
2.) Check the TorqueMaster® tube and flagangles for level and plumb.
3.) Check the distance between the flagangles must be door width plus 3-3/8” to 3-1/2”.
4.) Check the counterbalance cables for equal tension adjust if necessary.
5.) Rewind the spring(s).
6.) Make sure door isn’t rubbing on jambs.
After door installation is completed and you
have installed an idrive® opener, refer to
Steps 15 thru 32 in your idrive® Installation
Instruction/Owner’s Manual.
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local 29
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
INSTALLATION
Rear Support Continued...
Angle bolted to ceiling
member and parallel to
door
❉
Tools Needed:
5/8” Socket
Ratchet Wrench
3” Extension
Vice Clamps
(Pair)
3” Extension
ENGAGEMENT SIDE VIEW
TorqueMaster® Plus Reset
Instructions
WARNING
To avoid possible injury, READ THESE
INSTRUCTIONS CAREFULLY BEFORE
ATTEMPTING TO RESET THE TORQUEMASTER® PLUS SYSTEM. IF IN QUESTION
ABOUT ANY OF THE PROCEDURES, DO
NOT PERFORM THE WORK. INSTEAD,
HAVE A QUALIFIED DOOR INSTALLATION
COMPANY RESET THE SYSTEM.
Ratchet
Pawl
Cable Drum
WARNING
ALWAYS KEEP MOVING DOOR IN SIGHT
AND KEEP PEOPLE AND OBJECTS AWAY
UNTIL IT IS COMPLETELY CLOSED. TO
PREVENT A SEVERE OR FATAL INJURY,
AVOID STANDING IN A OPEN DOOR WAY
OR WALKING THROUGH THE DOORWAY
WHILE THE DOOR IS MOVING.
Drum Pawl
ENGAGEMENT Underneath View
No space between
drum Pawl and Cable
Drum
Indicates engagement
WARNING
KEEP THE GARAGE DOOR PROPERLY BALANCED. AN IMPROPERLY BALANCED DOOR
COULD CAUSE SEVERE OR FATAL INJURY.
HAVE A QUALIFIED DOOR INSTALLATION
COMPANY MAKE ADJUSTMENTS/REPAIRS
TO CABLES, SPRING ASSEMBLIES AND
OTHER HARDWARE.
This door is equipped with a Torquemaster® Plus system, which provides a safety
feature preventing the door from rapidly
descending in case of spring failure or
forceful manual operation. Typical signs of
an engaged system: Door opens, but will
not close; door makes a distinct “clicking”
noise upon opening. If the system is engaged, carefully follow the reset instructions below in conjunction with
the door’s Installation Instructions and
Owner’s Manual to reset the Torquemaster® Plus system.
Instruction manuals are available for
download at www.Wayne-Dalton.com.
RESETTING THE ANTI-DROP DEVICE
1. First, locate and visually inspect the
Torquemaster® Plus end brackets to
determine if the system has engaged
(see illustration on reverse side). NOTE:
The Torquemaster® Plus end brackets are
located on top of the door on the right and
left hand side.
NOTE: If the Torquemaster® Plus system
has not engaged, do not complete the
following steps.
No space between
drum Pawl and
Cable Drum
NON-ENGAGEMENT SIDE VIEW
Cable Drum
Drum Pawl
NON-ENGAGEMENT Underneath View
Space between DRUM Pawl
and Cable Drum
Non-indicates engagement
Space between
drum Pawl and
Cable Drum
30 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
TorqueMaster® Plus Reset
Instructions Continued...
If the system is engaged, follow these
steps to reset the system:
2. Disengage opener (if installed) by pulling or placing emergency disconnect
in the manual operated position.
3. With the door in the open position,
clamp vice grips on both tracks just below
the bottom section roller.
4. Now is a good time to remove vehicles
from garage, and provide clear access to
end brackets.
5. Flip the ratchet pawl knob on both
end brackets to the upper position (see
illustration).
6. Raise door 2”-3” and then lower door.
Repeat process until anti-drop device
resets (see disengaged illustrations on
reverse side).
IMPORTANT: BE PREPARED TO SUPPORT
THE TOTAL WEIGHT OF THE DOOR.
7. Cautiously remove the vice clamps from
both tracks and with assistance lower the
door.
8. Check for spring tension. Starting on
the right hand side, place a ratchet and
5/8” socket on the Torquemaster® Plus
winding shaft (see illustration in instruction manual). Ensure ratchet is set
so that it will tighten counter clockwise on
the right hand side, and clockwise on the
left hand side (if applicable). If tension is
present, remove the ratchet and check the
left hand side (if applicable). If spring(s)
have tension, proceed to Balancing Door
Step 1; if no spring tension is present,
contact a qualified door installation company to replace the spring(s).
IMPORTANT: HAVE A QUALIFIED DOOR
INSTALLATION COMPANY MAKE ADJUSTMENTS/REPAIRS TO CABLES,
SPRING ASSEMBLIES AND OTHER HARDWARE.
BALANCING DOOR
1. Lift door and check its balance. Adjust
spring(s), if door lifts by itself (hard to pull
down) or if door is difficult to lift (easy to
pull down). Anytime spring adjustments
are made, ratchet pawl knob must be
in the upper position (see illustration on
reverse side). An unbalanced door such as
this can cause idrive® or Torquemaster®
Plus operation problems.
Place vice clamps
BELOW BOTTOM SECTION
on both vertical track
INSTALLATION
Tools Needed:
Lower Position
UPPER Position
Pawl Knob in Lower
Position
Pawl knob in UPPER
Position
End Bracket
Ratchet
with 5/8”
Socket
Use
this these
lab Illustr
el.
atio
n, in
PAWL
WA
R
con
jun
ctio
3” Extension
NIN
Ra
n wit
ch
h the
EX et Br
Ins
tru
ac
TR
ctio
ke
ENG
EM
ns
AGE
t is
To
on
DE
the
E VIEW unde
fataavoidTENSSIDSP
oth
RI
er sid
fast l inju poss ION. NG r
e of
en ry,
ib
er
DO le se
un s fro
til sp m NOT vere
rin ratche rem or
To
ENG
g(
AGE
sa wn s) ar t br ove
D UND
wo
fe
ac
anERNEAT ly un und.e fully ket
d H VIE
wind
inst follo
W
alla w th read sprin
tio e di
g(s)
n in re
DO
stru ctio
NO
Ratc
ns
ct
m
Cab
T RE an het
ions in
le Drum
ua Paw
MO l. l /ownthe
No
spac
VE
ers
Ratc e betw
TH
het
een
Paw
IS No space
Cab
l
TAPaw between
le Drumand
Gl and Cab Ratc
indic.
G
DIS
ENG
ates
AGE
D SID
le Drumhet
age
men
t
eng
E VIEW
DIS
ENG
AGE
D UND
ERN
EAT
H VIEW
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local 31
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Ratc
het
No
ER
Paw
spac
Ratc e betw
het
een
Paw
Cab
l
le Drumand
ITIO
N
UPP
Cab
l
le Drum
Spa
ce
POS
betw
een
and
Ratc
Cab
het
-ind
le
icate Drum Pawl
s eng
age
men
t
non
LOW
ER
POS
ITIO
N
Ratc
het
Paw
l in
Upp
er Pos
ition
UPP
ER
Ratc
het
POS
ITIO
Paw
l in
N SID
E VIEW
Low
er Pos
ition
LOW
ER
POS
ITIO
N SID
E VIEW
TorqueMaster® Plus Reset
Instructions Continued...
Tools Needed:
To adjust spring(s), only add or remove a
maximum of 3/10 of a turn (three teeth of
ratchet wheel) at a time. Both sides need
to be adjusted equally on double spring
doors.
NOTE: Single spring applications require
no spring winding on left hand side.
Clamp a pair of vice clamps on the vertical
tracks just above the second roller on one
side and just below the second roller on
the other side. This will prevent the door
from raising or lowering while adjusting
the spring(s).
Place vice clamps
above 3rd Roller on
both vertical track
Vice clamps
attached to
track
Track
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.
To Add Spring Tension: The ratchet
wheel is made of 10 teeth. To add spring
tension, ensure the ratchet and socket is
set so that it will tighten counter clockwise
on the right hand side, and clockwise on
the left hand side. Place the ratchet with
5/8” socket onto the winding shaft, pull
down to add 3/10 of a turn. Watch as
three teeth of the ratchet wheel pass over
the pawl, creating three “clicks”.
To Remove Spring Tension: To remove
spring tension, ensure the ratchet and
socket is set so that it will tighten counter
clockwise on the right hand side and
clockwise on the left hand side. Place the
wrench onto the winding shaft. Pull down
on the ratchet to relieve pressure between
the pawl and the ratchet wheel. Push in on
the pawl to allow the three ratchet wheel
teeth to pass by the pawl, as you carefully
allow the ratchet wrench to be rotated
upward by the spring tension. Release the
pawl to allow it to engage with the ratchet
wheel.
Remove the vice clamps from the vertical
tracks, re-check door balance and adjust
if necessary. When door is balanced and
adjusted properly, place the ratchet pawl
knobs in the active position (lower position).
UPPER Position
Lower Position
Pawl knob in Lower
Position
Pawl knob in upper
Position
End Bracket
Ratchet
with 5/8”
Socket
Use
this these
lab Illustr
el.
atio
PAWL
n, in
WA
R
con
jun
ctio
3” Extension
NIN
Ra
n wit
ch
h the
EX et Br
Ins
tru
ac
TR
ctio
ke
ENG
EM
ns
AGE
t is
To
on
DE
the
E VIEW unde
fataavoidTENSSIDSP
oth
RI
er sid
fast l inju poss ION. NG r
e of
en ry,
ib
er
DO le se
un s fro
til sp m NOT vere
rin ratche rem or
To
ENG
g(
AGE
sa wn s) ar t br ove
D UND
fely wo
ac
e
un
anERNEAT
fully ket
d H VIE unwi d.
nd
inst follo
W
alla w th read sprin
tio e di
g(s)
n in re
DO
ctio
st
NO
ns
cthet
manruRatc
Cab
T RE
ioPaw
le
in
Drum
ua ns
MO l. l /ownthe
No
spac
VE
ers
Ratc e betw
TH
het
een
Paw
IS No space
Cab
l
TAPaw between
le Drumand
Gl and Cab Ratc
indic.
G
DIS
ENG
ates
AGE
D SID
le Drumhet
age
men
t
eng
E VIEW
32 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
DIS
ENG
AGE
D UND
ERN
EAT
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
H VIEW
Ratc
het
No
ER
Paw
spac
Ratc e betw
het
een
Paw
Cab
l
le Drumand
ITIO
N
UPP
Cab
l
le Drum
Spa
ce
POS
betw
een
and
Ratc
Cab
het
-ind
le
icate Drum Pawl
s eng
age
men
t
non
LOW
ER
POS
ITIO
N
Ratc
het
Paw
l in
Upp
er Pos
ition
UPP
ER
Ratc
het
POS
ITIO
Paw
l in
N SID
E VIEW
Low
er Pos
ition
LOW
ER
POS
ITIO
N SID
E VIEW
❉
Tools Needed:
Power Drill
7/16” Socket
Driver
1/8”
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
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 10 on page 16.
(4) 1/4”- 20 x 11/16”
self drilling screws
Tools Needed:
Power Drill
1/8” Drill Bit
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. Tie the pull rope to the No. 6 screw
eye and to the bottom bracket as shown.
NO. 6 Screw EYE
Optional INSTALLATION
❉
Pull Rope
PULL ROPE
WARNING
DO NOT INSTALL PULL ROPES
ON DOORS WITH ELECTRIC
OPERATORS. CHILDREN MAY
BECOME ENTANGLED IN THE
ROPE CAUSING SEVERE OR FATAL
INJURY.
BOTTOM BRACKET
PULL ROPE
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local 33
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Trolley Operator
Tools Needed:
None
Align hole in the appropriate arm with
holes in operator bracket tabs. Insert
5/16” x 1-1/4” clevis pin, making sure
hole in clevis pin is outside of second
tab of operator bracket. Insert hairpin
cotter into clevis pin hole and spread
hairpin cotter to ensure it will secure
assembly. Operator must be tested at
time of installation and monthly there
after to ensure that door reverses on
contact with 2” x 4” board laid flat under
the door. Failure to pass this test requires
immediate adjustments or repairs.
Operator
Bracket
tabs
Operator Hairpin
Bracket Cotter
5/16” x 1-1/4”
Clevis pin
Door
Arm
Hairpin Cotter
(Outside of operator
bracket tab)
SUITABLE
MOUNTING
SURFACE (2 X 6)
LUMBER MIN.
WARNING
FAILURE TO MAKE ADJUSTMENTS
OR REPAIRS, 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 pass this test
requires immediate adjustments or
repairs.
HEADER
Operator
bracket tabs
DOOR ARM TO OPERATOR
BRACKET
Top view
WARNING
OPERATOR
rail
FAILURE TO MAKE ADJUSTMENTS
OR REPAIRS, IF NECESSARY, CAN
RESULT IN SEVERE OR FATAL
INJURY.
1. Install operator rail 1/2” to 1”
(13 mm - 38 mm) above high arc of top section of the door.
2. Mount operator to ceiling so that
1” to 1-1/2” (25 - 38 mm) clearance is maintained between trolley rail and top section when door is fully open (trolley rail will
slope down towards rear).
3.Attach door arm to operator bracket installed in Step 9.
4. Attach operator rail to suitable mounting surface, 2” x 6” lumber minimum.
5.Attach operator to ceiling using perforated angle.
IMPORTANT! Perforated Angle must
be securely attached to sound
framing member(s).
OPERATOR
RAIL
Door arm
Perforated
angle
OPERATOR
FRAMING
MEMBERS
PERFORATED ANGLE
34 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Cleaning Your Steel And Fiberglass Garage Door
IMPORTANT: DO NOT USE A PRESSURE WASHER ON GARAGE DOOR!
While factory-applied finishes on garage doors are durable, it is desirable to clean them on a routine basis. Some discoloration of the
finish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result
of direct exposure to sunlight.
Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, a
periodic washing of the garage door is recommended.
The following cleaning solution is recommended:
A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into five gallons of warm water will
aid in the removal of most dirt.
NOTES: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.
NOTES: Be sure to clean behind weather stripping on both sides and top of door.
CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.
GLASS CLEANING INSTRUCTIONS
Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.
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. To find your local Wayne-Dalton dealer, refer to your local 35
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Optional INSTALLATION
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.
Steel Preparation For Painting
Steel (Surface Preparation for Painting)
Wax on the surface must be removed or paint peeling/flaking will result. To remove this wax, it will be necessary to lightly scuff the
surface with a fine steel wool pad, saturated with soapy water. A final wipe and rinse should be done with clean water only, to remove
any loose particles and any soapy film residue.
Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or No. 400
sand paper to create a smoother surface. Care must be taken to not expose the substrate under the paint. Once the substrate is
exposed, the likelihood for rusting is greatly increased.
If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed area lightly and paint with a high quality
metal primer, specifically intended for galvanized surfaces, to protect the area from corrosion. Allow for drying time on primer can label
before applying topcoat.
The surface of the factory-applied finish, that is being painted, must not be too smooth, or the paint will not adhere to it. It is
advisable to test in an inconspicuous area, to evaluate adhesion. If poor adhesion is observed, surface preparation for painting the
factory-applied finish must be repeated until desired results are achieved. Again, care must be taken to not expose the substrate under
the paint.
Steel (Painting)
After surface has been properly prepared, it must be allowed to dry thoroughly, and then coated immediately with premium quality
latex house paint. Follow paint label directions explicitly. Oil base or solvent base paints are not recommended. Please note that if
substrate is exposed and not properly primed, painting with latex paint may cause accelerated rusting of the steel in the exposed area.
NOTES:
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 all liability for the finishing.
36 Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
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Lifetime Limited Warranty
Model 9800
(i)
Delamination of the fiberglass skin or peeling of the original factory-applied coating on the door as a result of a defect in the original fiberglass skin where the door sections and the original fiberglass skin and factory-applied coating: (a) have not been subjected to adverse atmospheric conditions or contaminates (such as salt water or other marine environment, or to toxic or abrasive substances, including those in the air); (b) have been maintained in compliance with Manufacturer’s recommendations; and (c) have not been subject to physical abrasion, impacted by a hard objects, or have been punctured.
(ii)
The door becoming inoperable due to rust-through of the steel skin backer from the core of the door section, caused by cracking, splitting, or other deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.
(iii)
Peeling, cracking, chalking or fading of the factory-applied coating, from the time of installation. If the door is re-stained or re-painted, the warranty for the factory-applied coating is void.
The Manufacturer warrants the garage door hardware (except springs) and the tracks of the above-described door, for as long as you own the door, against
defects in material and workmanship, subject to all the terms and conditions below.
The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Lifetime Limited Warranty against defects in
material and workmanship for a period of ONE (1) YEAR from the date of installation.
After a period of TWENTY (20) YEARS, from time of installation, replacement of Lifetime Limited Warranty materials will be pro-rated at 50 per cent of
Manufacturer’s published list pricing at time of claim, and you must pay this amount.
This Limited Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as his/her
primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or to installations on
rental property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the premises is sold), nor does it
extend benefits to any other person. As a result this Limited Warranty does NOT apply to any person who purchases the product from someone other than an authorized
Wayne-Dalton dealer or distributor.
The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its
components, abuse, damage from corrosive fumes or substances, salt spray or saltwater air, fire, Acts of God, failure to properly maintain the door, or attempt to use the
door, its components or related products for other than its intended purpose and its customary usage. This Limited Warranty does not cover ordinary wear.
This Limited Warranty will be voided if any holes are drilled into the door, other than those specified by the Manufacturer.
THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS ACT. NO WARRANTIES, EXPRESS OR IMPLIED (INCLUDING
BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN
UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY, ABOVE.
•Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.
Any claim under this Limited Warranty must be made in writing, within the applicable warranty period, to the dealer from which the product was purchased.
Unless the dealer is no longer in business, a written claim to the Manufacturer will be the same as if no claim had been made at all.
At the Manufacturer’s option, pursuant to the dealer having notified the Manufacturer of a warranty claim, a service representative may inspect the product on
site, or Buyer may be required to return the product to the Manufacturer at Buyer’s expense. Buyer agrees to cooperate with any representative of the Manufacturer and
to give such representative full access to the product with the claimed defect and full access to the location of its installation.
If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty, the Manufacturer will cause the defective product to be
repaired or replaced. The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer, subject to applicable law. THE
REMEDY WILL COVER ONLY MATERIAL. THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES, SUCH AS FIELD SERVICE LABOR FOR REMOVAL, INSTALLATION,
PAINTING, SHIPPING, ETC.
Any repairs or replacements arranged by Manufacturer will be covered by (and subject to) the terms, conditions, limitations and exceptions of this Limited
Warranty; provided, however, that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed, and this
Limited Warranty will expire at the same time as if there had been no defect. If a claim under this Limited Warranty is resolved in a manner other than described in the
immediately preceding paragraph, then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the
product.
THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy. The liability of the
Manufacturer, whether in contract or tort, under warranty, product liability, or otherwise, will not go beyond the Manufacturer’s obligation to repair or replace, at its option,
as described above. THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, including
(but not limited to) damage or loss of other property or equipment, personal injury, loss of profits or revenues, business or service interruptions, cost of capital , cost of
purchase or replacement of other goods, or claims of third parties for any of the foregoing.
•Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.
No employee, distributor, dealer, representative, or other person has the authority to modify any term or condition contained in this Limited Warranty or to
grant any other warranty on behalf of or binding on the Manufacturer, and anyone’s attempt to do so will be null and void.
Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer.
The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio, USA, to the extent
permitted by law.
•
This Limited Warranty gives you 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. To find your local Wayne-Dalton dealer, refer to your local 37
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Maintenance
Subject to the terms and conditions contained in this Lifetime Limited Warranty, Wayne-Dalton (“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:
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.
38
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local
yellow pages business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com