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9800 Series - 4 Section
Low Head Room Front Mount
Torsion Spring
Installation Instructions and Owner’s Manual
IMPORTANT NOTICE!
Wayne-Dalton Corp.
Read these instructions carefully before
P.O. Box 67 attempting installation. If in question about
any of the procedures, do not perform the
Mt. Hope, OH 44660
work. Instead, have a qualified door agency
www.wayne-dalton.com
do the installation or repairs.
Copyright 2009 Wayne-Dalton Corp. Part No. 341785 REV1 08-03-2009
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WARNING Table of Contents TO AVOID POSSIBLE Important safety Instructions .................................................. 2 INJURY, READ ThESE INSTRUCTIONS Package Contents ................................................................... 3 CAREfULLY BEfORE ATTEMPTING Door section Identification ...................................................... 4 Tools Required ........................................................................
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NOTE: DEPENDING ON ThE DOOR MODEl, sOME P aRTs lIsTED WIll NOT bE suPPlIED IF NOT NECEssaR y. REaR Package Contents suPPORTs May OR May NOT bE INCluDED WITh yOuR DOOR. DOOR sECTIONs (as REquIRED) (1) TORsION TubE (2) hORIzONTal TRaCk Rh/lh (2) Fully aDjusT ablE Rh/lh (2) quICk INsT all Rh/lh FlaGaNGlE (as REquIRED) FlaGaNGlE (as REquIRED) RIGhT & lEFT DR uMs TORsION sPRINGs (2) bOTTOM bRaCkETs (1) OPERaTOR bRaCkET (2) TOP bRaCkET (as REquIRED) (2) VERTICal q.I. jaMb bRaCkETs Fully aDjusT abl
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Door Section Identification Tools Needed: NOTE: This provides an alternative method for identifying your door sections/stacking position. TOP sECTION hinges are always pre-attached at the top #3 of each section (except top section) and the hinges are stamped for identification, WaRNING labEl #1, #2, #3, and #4 (#4 only on five (MaybE ON RIGhT section doors). see view below. The OR lEFT haND sIDE) stamp identifies the stacking sequence of the section. The sequence is always determined
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Tools Required PENCIl POWER DRIll RaTChET WRENCh TaPE MEasuRE 1/8”, 3/16” DRIll bITs lEVEl aPPROVED WINDING baRs PhIllIPs hEaD sCREWDRIVER Fla T TIP sCREWDRIVER GlOVEs 1/4” TORx bIT 7/16”, 1/2”, 3/8”, 9/16” 7/16”, 1/2”, 9/16” 7/16” sOCkET DRIVER saFETy GlassEs sOCkETs WRENChEs sTEP laDDER haMMER sa W hORsEs (P aIR) VICE GRIPs VICE ClaMPs 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 ha VE
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Torsion Spring Removal P1 for Standard Lift Tools Needed: WARNING TORsION sPRING assEMbly FaIluRE TO usE aPPROVED approved WINDING baRs CaN CausE sPRING Winding bars ENERGy TO bE RElEasED suDDENly, REsul TING IN sEVERE 3/8” Wrench OR FaTal INjuR y. (2) Vice Clamps WARNING Recommended COuNTERbalaNCE sPRING tools from TENsION MusT bE RElIEVED page 5 bEFORE REMOVING aNy WINDING CONE haRDWaRE. a POWERFul sPRING RElEasING IT’s ENERGy suDDENly CaN CausE sEVERE OR F aTal INjuR y. Do not rele
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lOOsEN lOCk COuNTER ® TorqueMaster Spring Removal NuT GEaR/ COVER P2 ® a TorqueMaster spring system can be Tools Needed: identified by the end brackets. For single spring applications, the right hand end RIGhT haND bracket will always have a drive gear, Recommended END bRaCkET counter gear, counter cover, and a winding tools from bolt head. The left hand end bracket will page 5 have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged. Fo
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® TorqueMaster Spring Removal continued... (spring Tube should be free to rotate in Tools Needed: either direction.) If the counterbalance ® cable is still taut and the TorqueMaster Recommended spring Tube is difficult to rotate, that is an tools from indication that spring tension still exists page 5 on the left hand spring. Repeat steps 1 and 2 for releasing spring tension on the left hand side. REMOVE TOP laG sCREW Step 4: using a flat tip screwdriver, pry the counter gear and cou
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REMOVE laG sCREW FROM saFETy CablE (IF Extension Spring Removal INsTallED). REPEa T FOR P3 OPPOsITE sIDE. Step 1: Raise the door to the fully open Tools Needed: position and place vice clamps to the back Recommended legs of both vertical tracks, below the tools from bottom rollers to prevent the door from page 5 falling. by opening the door you release most of the spring tension. Carefully bOTTOM sECTION unfasten the s-hook from the horizontal (DOOR OPEN) angle. Remove cable, sheave and
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suITablE MOuNTING suRFaCE 2” x 6” hEaDER bOaRD Preparing the Opening luMbER MINIMuM 2” x 6” luMbER P5 PREFERRED FaIluRE TO sECuREly Tools Needed: WARNING aTTaCh a suIT ablE Recommended MOuNTING PaD TO sTR uCTuRally sOuND FRaMING DOOR hEIGhT COulD CausE sPRINGs TO VIOlENTly Pull MOuNTING tools from PaD FROM Wall, REsul TING IN sEVERE OR FaTal INjuR y. lEVEl hEaDER page 5 If you just removed your existing door or you are installing a new door, complete all steps in PREPaRING ThE PluMb j
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Installation IMPORTANT: REaD INsTR uCTIONs TITlED “P4” “REMOVING ThE OlD DOOR” ON P aGE 9 aND “P5” “PREPaRING ThE OPENING” ON PaGE 10 bEFORE aTTEMPTING DOOR INsTalla TION. IMPORTANT: sTaINlEss sTEEl OR PT 2000 COa TED laG sCREWs MusT bE usED WhEN INsTallING CENTER bEaRING bRaCkETs, END bRaCkETs, jaMb bRaCkETs, OPERa TOR MOuNTING/suPPORT bRaCkETs aND DIsCONNECT bRaCkETs ON TREaTED luMbER (PREsERVaTIVE-TREaTED). sTaINlEss sTEEl laG sCREWs aRE NOT NECEssaR y WhEN INsTallING PRODuCTs ON uN-TREa
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Fully aDjusT ablE FlaGaNGlE Attaching fully Adjustable flagangle to Vertical Track 2 Tools Needed: NOTE: If quick install flagangle was installed in step 1, skip this step and None continue with step 3. If not, complete 1/4”- 20 this step. FlaNGE hEx NuTs 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 sTuD Pla TE included) and (2) 1/4” - 20 flange hex (IF INCluDED) nuts. Repeat for other side. secure the fla
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Fully aDjusT ablE jaMb bRaCkETs Installing fully Adjustable Jamb Brackets 4 Tools Needed: NOTE: If quick install flagangles were installed in step 3, skip this step and None continue with step 5. If not, complete sT-0 sT-1 this step. The bottom jamb bracket is always the hOlE/slOT shortest bracket included with your jaMb PaTTERN bRaCkET door. If three jamb brackets are included with the door, the middle bracket on the (1) 1/4”-20 x 9/16” TRaCk bOl T track is the middle bracket in heig
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bOTTOM (4) 1/4”-20 x 11/16” sElF Bottom Bracket sECTION DRIllING sCREWs 5 ClEVIs PIN IMPORTANT: Right and left hand is Tools Needed: always determined from inside the TEaRDROP OF Power Drill COuNTERbalaNCE garage looking out. CablE 7/16” socket NOTE: For door section identification see Driver page 4. locate the left hand bottom bracket. bOTTOM align the bracket horizontally with the bOTTOM bRaCkET top edge of the pre-installed bottom bRaCkET bracket. also align the bracket vertical
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Bottom Section 6 DOOR OPENING Tools Needed: before installing the bottom section, the weather seal (may not be included) level must be installed (see PREPaRING ThE OPENING on page 10) Center the bottom section in the door opening. level section using wooden shims (if necessary) under the bottom astragal. WEaThER sEal lEVEl bOTTOM sECTION WOODEN shIMs (IF NECEssaR y) VERITCal TRaCk bOTTOM sECTION Vertical Track FlaGaNGlE 7 Tools Needed: IMPORTANT: ThE TOPs OF ThE 5/16” x 1-5/8” VERTICal
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Stacking Sections 8 NOTE: For door section identification see Tools Needed: page 4. lOCk sECTION Power Drill 7/16” socket NOTE: Make sure hinge leafs are flipped Driver down, when stacking another section on top. Place rollers in hinge tubes of the second section (lock section). With assistance, lift second section and guide rollers into the vertical tracks. align vertical marks in the upper alignment sticker, with the lower alignment sticker on right hand side on the back of door. k
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u-baR Operator Bracket 9 NOTE: If installing a trolley type Tools Needed: operator, complete this step. If not, skip Power Drill sIDE VIEW OF u-baR this step and continue with step 10. 7/16” socket Driver IMPORTANT: WhEN INsTallING a 1/4”-20 x 7/8” sElF TROllEy TyPE OPERaTOR ON 9800 DRIllING sCREWs DOOR, a WayNE-Dal TON TROllEy bRaCkET MusT bE sECuREly aTTaChED TO ThE TOP sECTION. IT Is ThEN uNNECEssaR y TO FuRThER REINFORCE ThE TOP sECTION OF ThE MODEl 9800 WayNE-Dal TON DOOR, W
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Top Section DOOR WIDTh 10 +3-3/8” TO 3-1/2” Tools Needed: Place the top section in the opening and vertically align with lower sections. hammer align vertical marks in the upper 7/16” socket alignment sticker, with the lower alignment sticker on right hand side on 7/16” Wrench the back of door. Ratchet Wrench Temporarily secure the top section by driving a nail in the header near the 7/16” socket center of the door and bending it over Driver the top section. Power Drill Now flip up hin
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Attaching horizontal Track to FlaGaNGlE hORIzONTal TRaCk quick Install flagangle 11 Tools Needed: NOTE: If you have fully adjustable flagangle, skip this step and complete kEy slOT 7/16” socket step 12. Ratchet Wrench quICk To install horizontal track, align key slot INsTall of the horizontal track with the quick Tab 7/16” Wrench install tab of the flagangle. Push curved portion of horizontal track down to lock level VERTICal in place. TRaCk level horizontal track and bolt the top cur
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Attaching horizontal Track to Adjustable flagangle 12 Tools Needed: FlaGaNGlE NOTE: If quick install flagangle was installed in step 11, skip this step and 7/16” socket continue with step 13. If not, complete this step. Ratchet Wrench sTuD Pla TE To install horizontal track, place the 7/16” Wrench curved end over the top roller. align the bottom of the horizontal track with level the vertical track. hand tighten the horizontal track to the flagangle with Flat Tip (1) stud plate and (
