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9800 Light Commercial Windload
Torsion 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
Wayne-Dalton Corp.
work. Instead, have a trained door systems
P.O. Box 67
Mt. Hope, OH 44660 technician do the installation or repairs.
www.wayne-dalton.com
Copyright 2009 Wayne-Dalton Corp. Part No. 334948 REV2 08/03/2009
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TO AvOID POSSIblE Table of Contents WARNING Important safety Instructions .................................................. 2 INjUR y, READ ThESE Package Contents ................................................................... 3 INSTRUCTIONS CAREfUlly bEfORE ATTEMPTING Door section Identification ...................................................... 4 INSTAllATION. If IN qUESTION AbOUT ANy Of Tools Required ............................
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NOTE: DEPENDING ON ThE DOOR MODEl, sOME P aRTs lIsTED WIll NOT bE suPPlIED IF NOT Package Contents NECEssaR y. REaR suPPORTs May NOT bE INCluDED WITh yOuR DOOR. DOOR sECTIONs (as REquIRED) TORsION TubE (2) hORIzONTal TRaCks Rh/lh OPERaTOR bRaCkET (2) hORIzONTal aNGlEs Rh/lh TORsION sPRINGs RIGhT & lEFT (May bE sPOTWElDED) DRuMs (as REquIRED) (2) VERTICal TRaCk assEMblIEs (2) TOP bRaCkETs assEMblIEs Rh/lh DOOR sTOP & NaIls WEaThER sEal & NaIls (IF INCluDED) Pull ROPE & sCREW ROllERs (IF INClu
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sECTION sIDE VIEWs Door Section Identification (TOP OF sECTIONs shOWN) TOP Tools Needed: hinges are always pre-attached to the top of each section (except top section). see illustrations to the right. The bOTTOM SECTION can be identified by the factory attached bottom astragal and by the bottom 1-9/16” bracket warning labels on each end stile. INTERMEDIaTE II (NOT ON a FOuR sECTION DOOR, FIVE sECTION DOOR ONly) The lOCk SECTION can be identified by section side view. The INTERMEDIATE I SECTI
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backroom IMPORTANT: COuNTERbalaNCE sPRING TENsION Removing An Existing Door MusT al Ways bE RElEasED bEFORE aNy a TTEMPT Is MaDE TO sTaRT REMOVING aN ExIsTING DOOR. Tools Needed: WARNING a POWERFul s PRING REl Eas ING ITs ENERGy su DDENly CaN Caus E sEVERE OR FaTal INju Ry. TO aVOID INju Ry ha VE a TRaINED DOOR sysTEMs TEChNICIaN, usING PROPER TOOls aND INsTR uCTIONs, RElEasE ThE sPRING TENsION. For detailed information see supplemental instructions “Removing an Existing Door /Preparing the O
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Installation begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb with header. side clearance, from edge of door to wall, must be a minimum of 3-1/2” (89mm) on each side. 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
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COuNTERbalaNCE END hINGE CablE Counterbalance Cables (hINGE TubE) 2 Tools Needed: IMPORTANT: RIGhT aND lEFT haND Is al Ways DETERMINED FROM INsIDE None ThE buIlDING lOOkING OuT . NOTE: For door section identification bOTTOM sECTION bOTTOM sECTION see page 4. uncoil the counterbalance cables and ROllERs slip the loop at the ends of the cables over the milford pins on the bottom section. Insert a short shaft roller in the bottom bracket on the bottom section and a long shaft roller in t
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9800 Windload U-bar Schedule Option Code 1221 Total Bottom Lock Intermediate Intermediate II Top Sections 4 2 u-bars 2 u-bars 3 u-bars 1 u-bar Tools Needed: To install a u-bar across the middle of a 5 2 u-bars 2 u-bars 2 u-bars 3 u-bars 1 u-bar section, align the horizontal center line of the u-bar with the center line of the section. For Windload specification option codes 1200, 1201, and 1202, all u-bars must be attached with 1 fastener at each hole location along the u-bar, which
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bottom Section 4 Tools Needed: Center the bottom section in the door opening. level section using wooden level shims (if necessary) under the bottom section. lEVEl bOTTOM sECTION WOODEN shIMs (IF NECEssaR y) vertical Track Assembly Wall aNGlE 5 ClIP MOuNT (yOuR ClIP MOuNT quaNTITy aND lOCa TION May VaRy) Tools Needed: IMPORTANT: ThE TOPs OF ThE VERTICal TRaCks MusT bE lEVEl FROM sIDE TO sIDE. Power Drill IF ThE bOTTOM sECTION Was shIMMED 3/16” Drill bit TO lEVEl IT . ThE VERTICal TRaCk
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Stacking Sections 6 Tools Needed: NOTE: For door section identification see page 4. Power Drill 7/16” socket NOTE: Make sure hinge leafs are flipped lOCk sECTION 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 the vertical lines on the alignment stickers, located on the right hand side on the back of the door sections. also, hING
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Top brackets 7 u-baR TOP bRaCkET basE Tools Needed: Place the top bracket base against the bottom of the u-bar, even with the edge (1) 5/16” - 18 NuT Power Drill of the endcap and fasten using 7/16” socket TOP sECTION (4) 1/4” - 20 x 7/8” self-drilling screws. Driver loosen the 5/16” - 18 nut. Repeat for shORT other side. shaFT (4) 1/4” - 20 x 7/8” ROllER sElF-DRIllING sCREWs The top bracket slide will be adjusted and tightened in step 11. ENDCaP Insert a short shafted roller into the
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Operator bracket u-baR 8 Tools Needed: NOTE: If installing a trolley type operator, complete this step. If not, skip Power Drill this step and continue with step 12. 7/16” socket Driver IMPORTANT: WhEN CONNECTING a 1/4”-14 x 1/2” sElF TROllEy TyPE GaRaGE DOOR OPENER DRIllING sCREWs TO ThIs DOOR, a WayNE-Dal TON OPENER/TROllEy bRaCkET MusT bE sECuREly aTTaChED TO ThE TOP sECTION OF ThE DOOR, alONG WITh aNy u-baRs PROVIDED WITh OPERaTOR ThE DOOR. ThE INsT alla TION OF ThE bRaCkET OPE
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Top Section 9 Place the top section in the opening NaIl Tools Needed: and vertically align with lower sections. hammer align vertical lines on the alignment stickers located on the right hand side step ladder on the back of the 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. Flip up hinge leafs, hold tight against section, and fasten center hinges first, and end hinges last. (Refer to step 6). P
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Attaching horizontal Track to Wall angle 10 WallaNGlE Tools Needed: To install horizontal track, place the curved end over the top roller. align 9/16” socket the bottom of the horizontal track with 7/16” socket the vertical track. hand tighten the horizontal track to the wallangle with Ratchet Wrench (2) 1/4”-20 x 9/16” track bolts and (2) 9/16” Wrench 1/4” - 20 flange hex nuts. Repeat for level other side. step ladder WARNING 1/4”-20 x 9/16” TRaCk bOl Ts DO NOT RaIsE DOOR uNTIl hORIz
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Adjusting Top brackets 11 TOP TOP With horizontal tracks installed, you can Tools Needed: sECTION sECTION now adjust the top brackets. Vertically Power Drill align the top section of the door with the lower sections. Once aligned, position 7/16” socket the top bracket slide, out against the Driver horizontal track. 7/16” Wrench CORRECT INCORRECT Maintaining the slide’s position, tighten the (1) 5/16” - 18 nut to secure the slide step ladder to the top bracket. Next lock the top slide i
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MOuNTING suRF aCE Center bearing bracket VERTICal lINE 13 Measure to locate the center of the door Equal Tools Needed: hORIzONTal DIsTaNCE and mark a vertical pencil line on the lINE Power Drill CENTER bEaRING mounting surface above the door, to bRaCkET indicate the center line of the door. Then, 7/16” socket CENTER OF measure from the center of the bearing, in Driver END bEaRING bRaCkET one of the end bearing brackets, DOWN to level the top of the door. using that dimension, Tape Me
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Equal sPaCING Tools Needed: NOTE: The set screws used on all torsion counterbalance winding cones CENTER and cable drums, are now colored red. bRaCkET DO NOT identify right and left hand by the set screw color. slide the nylon center bushing onto the torsion tube followed by the springs and cable drums. The nylon center bushing, springs and cable drums must be positioned, as shown. With assistance, pick up the torsion assembly and slide one end of the tube through one end bearing br
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CablE lEFT CablE DRuM Counterbalance Cables 16 Thread the counterbalance cables Tools Needed: around the back side of the left cable Vice Grips drum and verify that there is no cable 3/8” Wrench obstructions. hook the cables into the CablE drums. slide the left hand cable drum step ladder hOOkED IN against the left hand end bearing CablE DRuM bracket and tighten the set screws in the drum to 14-15 ft. lbs. of torque (Once set screws contact the tube, tighten screws one full turn). Rot
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Winding Torsion Spring(s) 18 Position a ladder slightly to the side of spring Tools Needed: so that the winding cone is easily accessible, step ladder yet your body is not in direct line with the winding bars. Check the label attached to the 3/8” Wrench spring warning tag for the required number of approved Winding complete turns to balance your door. 9’0” Door height = approx 9-5/8 Turns bars 10’0” Door height = approx 10-1/2 Turns CAUTION: usE WINDING baRs OF CORRECT DIaMETER TO WIND s
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DOOR IN ThE Rear Support PaRTIally OPEN 19 POsITION Partially, raise the door until the top section and half Tools Needed: of the next section are in a horizontal position. Do not raise door any further since rear of horizontal Ratchet Wrench track is not yet supported. 1/2” socket WARNING 1/2” Wrench RaIsING DOOR FuRThER CaN Vice Clamps REsul T IN DOOR FallING aND CausE sEVERE OR F aTal INjuR y. Clamp a pair of vice clamps onto the vertical VICE tracks just above the second roller on on
