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IMPORTANT NOTICES!

The complete Installation Instructions and Owner’s Manual are available at no

charge from:

Wayne-Dalton, a Division Of Overhead Door Corporation,

P.O. Box 67, Mt. Hope, OH., 44660, Or Online At www.Wayne-Dalton.com

Wayne-Dalton highly recommends that you read and fully understand

the Installation Instructions and Owner’s Manual before you attempt this

installation.

To avoid possible injury, read the enclosed instructions carefully before

installing and operating the garage door. Pay close attention to all

warnings and notes. After installation is complete, fasten this manual

near garage door for easy reference.

Front Mount Low HeadrooM

InstaLLatIon InstructIons and owner’s ManuaL

t o r q u e M a s t e r

P L u s

9800

Wayne-Dalton, a Division Of Overhead Door Corporation

Pre-Installation 2

Important Safety Instructions 2

Tools Required 2

Package Contents 2

Door Section Identiﬁcation 3

Removing an Existing Door 3

Preparing the Opening 3

Parts Breakdown 5

Installation 6

Optional Installation 14

TorqueMaster

Plus Reset Instructions 14

Door Arm Hookup 14

Inside Lock 14

Pull Down Rope 15

Maintenance 16

Cleaning Your Garage Door 16

Painting Your Garage Door 16

Fiberglass Reﬁnishing and Finishing 16

Operation And Maintenance 16

Warranty 18

Please Do Not Return This Product To The

Store. Please call 1-866-569-3799 (Press

Option 1) and follow the prompts to contact

the appropriate customer service agent. They

will be happy to handle any questions that

you may have.

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

346454

T a b l e O f C o n t e n t s

Part Number REV3 02/20/2013

Summary of content (20 pages)

PAGE 1
Ta b l e 9800 To r q u e M a s t e r ® P l u s Front Mount Low Headroom MH Installation Instructions And Owner’s Manual Please Do Not Return This Product To The Store Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.
PAGE 2
Pre-Installation IMPORTANT: Right and left hand is always determined from inside the building looking out Important Safety Instructions Tools Required Definition of key words used in this manual: Warning WARNING • Power drill • Drill bits: 1/8”, 3/16”, 7/16” • Ratchet wrench • Socket driver: 7/16” • Sockets: 7/16”, 1/2”, 9/16”, 5/8” • Socket extension: 3” Indicates a potentially hazardous situation which; if not avoided, could result in severe or fatal injury.
PAGE 3
Warning label Top section 5/16”-18 Hex nuts (as required) 3/8”- 16 Hex nuts (as required) 1/4”- 20 Flanged hex nuts (as required) #3 (2) 5/16” Washers Warning labels (Only on a 4 Section High Door) Intermediate section #2 3/8”-16 x 3/4” 1/4”-14 x 5/8” Self tapping Truss head bolts (as required) screws (as required) 1/4”-20 x 11/16” Self drilling screws (as required) Warning labels (Only on a 3 Section High Door) Lock section 1/4”-20 x 9/16” Track bolts (as required) #1 (2) 5/16”-18 x 3/4” Carriag
PAGE 4
side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and flush with the inside edge of the jamb. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.
PAGE 5
Parts Breakdown A1. NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations. A2. J6. J4. J9. I2. J1. K2. F1. J2. G1. C1. J8. A1. A2. H1. E1. J5. J7. C1. J3. B1. Top of vertical track Top of vertical track E2. F1. B2. B2. (Fully Adjustable Feature) 3rd hole set E3. I4. B1. E4. D2. B2. D1. 2nd hole set I1. B1. (Quick Install Feature) I6. 2nd hole set K1. Top hole C2. 1st hole set C1.
PAGE 6
Vertical track Installation 1st hole set Before installing your door, be certain that you have read and followed all of the instructions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door. NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com. 1 Quick Install Flag Angles Mounting flange Q.I.
PAGE 7
pattern. Secure jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side. To attach the center jamb bracket, locate lower hole of the hole / slot pattern of the 2nd hole set on the vertical track. Secure jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.
PAGE 8
Stacking Sections 10 Tools Required: Power drill, 7/16” Socket driver NOTE: The sections can be identified by the graduation of the factory installed end hinges. The smallest graduated end hinge on section should be stacked on top of the bottom section, with each graduated end hinge increasing as the sections are stacked, see Parts Breakdown. NOTE: Make sure graduated end and center hinges are flipped down, when stacking another section on top.
PAGE 9
Door width + 3-3/8” to 3-1/2” 13 Flag angle Nail TorqueMaster® Spring Tube Tools Required: None TorqueMaster® springs come lubricated and pre-assembled inside the TorqueMaster® spring tube. To prepare for install, lay the spring tube assembly on the floor, inside garage, in front of the door, and with the labeled end to the left.
PAGE 10
on top of the flag angles. NOTE: Cable drum assemblies are marked right and left hand. Cable drums and TorqueMaster® spring tube assembly is cam shaped to fit together only one way. Starting on the right hand side, pre-wrap the cable drum with the counterbalance lift cable 1-1/2 wraps, as shown. Position the TorqueMaster® spring tube assembly so the cam peak is pointing straight up. Slide the cable drum over the winding shaft until the cable drum seats against the TorqueMaster® spring tube assembly.
PAGE 11
seated in the first and second grooves of the cable drum. Pull on the end of the cable to remove all cable slack. Snug the set screw and then tighten an additional 1-1/2 turns. Measure approximately 6” of cable and cut off excess cable. Insert end of the cable into the hole of cable drum. Repeat for left hand cable drum assembly. IMPORTANT: Ensure the counterbalance lift cable is aligned and seated in the first and second grooves of the cable drum prior to winding springs.
PAGE 12
perforated angle (may not be supplied), (2) 5/16” x 1-5/8” hex head lag screws and (3) 5/16” bolts with nuts (may not be supplied), fabricate rear back hangs for the horizontal tracks. Attach the horizontal tracks to the rear back hangs with 5/16” - 18 x 1” hex bolts and nuts (may not be supplied). Horizontal tracks must be level and parallel with door within 3/4” to 7/8” maximum of door edge.
PAGE 13
roller. This is to prevent the garage door from rising while adjusting the counterbalance spring(s). IMPORTANT: To adjust springs, only add or remove a maximum of 3/10 of a turn (three teeth on the ratchet wheel) at a time. Both sides need to be adjusted equally on double spring doors. 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.
PAGE 14
Optional Installation TorqueMaster® Plus Reset Instructions Ratchet pawl Side view IMPORTANT: The drawbar operator force settings must be adjusted according to the manufacturer’s instructions. Some lighter weight doors are designed to operate with a single counterbalance spring.
PAGE 15
Pull Down Rope Warning WARNING Do not install pull down rope on doors with operators. Children may become entangled in the rope causing severe or fatal injury. Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the right or left side of jamb. Drill 1/8” pilot hole for no. 6 screw eye. Tie the pull down rope to the no. 6 screw eye and to the bottom corner bracket, as shown. No.
PAGE 16
Maintenance 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 top coat (A high-quality clear polyurethane) following the manufacturer instructions.
PAGE 17
Warning WARNING NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR LAG SCREWS ON THE COUNTERBALANCE (END OR CENTER BEARING BRACKETS) SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR. THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY, HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.
PAGE 18
Warranty Limited Warranty Model 9800 Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants to the original purchaser of the Model 9800 (“Product”), subject to all of the terms and conditions hereof, that the Product and all components thereof will be free from defects in materials and workmanship for the following period(s) of time, measured from the date of installation: • Limited Lifetime Warranty* - Against the Product becoming inoperable due to rust-through of the steel skin backer,
PAGE 19
PAGE 20
Thank you for your purchase. Please Do Not Return This Product To The Store Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have. After installation is complete, fasten this manual near garage door for easy reference.