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9800 DoorS
®
TorqueMaster Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
IMPor TANT NoTICE!
r ead these instructions carefully before attempting
Wayne-Dalton, a Division of
installation. If in question about any of the proce-
Overhead Door Corporation
dures, do not perform the work. Instead, have a
P.O. Box 67, Mt. Hope, OH 44660
qualified door agency do the installation or repairs.
www.Wayne-Dalton.com
©Copyright 2010 Wayne-Dalton, a Division of Overhead Door
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WArNINg To AVoID PoSSIBLE Table of Contents Important safety Instructions .................................................. 2 INJUr Y, rEAD ThESE INSTr UCTIoNS 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 Package Contents NECEssaR y. REaR suPPORTs May OR May NOT BE INCluDED WITH yOuR DOOR. 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. ©
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Door Section Identification TOP sECTION Tools Needed: NoTE: This provides an alternative method for identifying your door lOCk sECTION #3 sections/stacking position. WaRNING laBEl 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 #1 BOTTOM sECTION sequence of the section. The sequence BOTTOM BRaCkET is always determined by #1 being the asTRaGal W
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Tools required POWER DRIll RaTCHET WRENCH PlIERs/WIRE CuTTERs TaPE MEasuRE 1/8”, 3/16” DRIll BITs PHIllIPs HEaD sCREWDRIVER Fla T TIP sCREWDRIVER PENCIl NEEDlE NOsE PlIERs GlOVEs 3/8”, 7/16”, 1/2”, 9/16” 7/16”, 1/2”, 9/16” 7/16” sOCkET DRIVER saFETy GlassEs sOCkETs WRENCHEs sTEP laDDER HaMMER VICE GRIPs VICE ClaMPs (2) sa W 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 qualIFIE
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sET sCREWs Torsion Spring removal P1 for Standard Lift Tools Needed: WArNINg FaIluRE TO usE aPPROVED approved WINDING BaRs CaN CausE Winding Bars sPRING ENERGy TO BE RElEasED FIRMly HOlD WINDING suDDENly, REsul TING IN sEVERE BaR aND CauTIOusly 3/8” Wrench OR FaTal INjuR y. lOOsEN sET sCREWs Vice Clamp WArNINg COuNTERBalaNCE sPRING TENsION MusT BE RElIEVED Recommended WINDING CONE BEFORE REMOVING aNy tools from HaRDWaRE. a POWERFul page 5 sPRING RElEasING IT’s ENERGy suDDENly CaN
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lOOsEN lOCk ® COuNTER TorqueMaster Spring removal NuT 1/4 TuRN 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 Recommended bracket will always have a drive gear, END BRaCkET tools from counter gear, counter cover, and a winding 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 pl
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® TorqueMaster Spring removal Continued... should be free to rotate in either direction. Tools Needed: If the counterbalance cable is still taut and ® the TorqueMaster spring Tube is difficult Recommended to rotate, that is an indication that spring tools from tension still exists on the left hand spring. page 5 Repeat steps 1 and 2 for releasing spring tension on the left hand side. REMOVE TOP Step 4: using a flat tip screwdriver, laG sCREW pry the counter gear and counter cover from
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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 Recommended back legs of both vertical tracks, below tools from the bottom rollers to prevent the door page 5 from falling. By opening the door you release most of the spring tension. BOTTOM sECTION (DOOR OPEN) Carefully unfasten the s-hook from the horizontal angle. Remove cable, sheave
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suITaBlE MOuNTING suRF aCE 2” x 6” luMBER MINIMuM Preparing the opening P5 HEaDER BOaRD 2” x 6” luMBER If you just removed your existing door or you are installing a PREFERRED Tools Needed: new door, complete all steps in PREPaRING THE OPENING. Recommended To ensure secure mounting of track brackets, side DOOR tools from and center brackets, or steel angles to new or retro-fit HEIGHT lEVEl HEaDER page 5 construction, it is recommended to follow the procedures outlined in DasMa Technic
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Installation IMPor TANT: 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. IMPor TANT: sTaINlEss sTEEl OR PT2000 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 you have quick install jamb brackets, skip this step and complete step 5. None The bottom jamb bracket is always the sT-0 sT-1 shortest bracket included with your door. If three jamb brackets are included with you door, the second bracket up HOlE / slOT jaMB PaTTERN is the middle bracket in height. The BRaCkET top jamb bracket is the tallest bracket included. 1/4”- 20 x 9/16” TRaCk BOl
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Installing q.I. Jamb Brackets 5 NoTE: If you have fully adjustable jamb Tools Needed: brackets, skip this step and complete step Tape Measure 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 lEFT sIDE sHOWN RIGHT sIDE sHOWN bracket with the quick install feature in the TWIsTlOCk TOP 3RD sET HOlE
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Bottom Section Tools Needed: Before installing the bottom section, the weather seal (may not be included) level 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 WOODEN sHIMs (IF NECEssaR y) VERTICal TRaCk CaBlE FlaGaNGlE Vertical Track 8 5/16” x 1-5/8” laG sCREWs Tools Needed: IMPor TANT: TH
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(2) 1/4” - 14 x 5/8” sElF-T aPPING sCREWs Stacking Sections 9 NoTE: For door section identification see Tools Needed: alIGNMENT sTICkERs page 4. RIGHT END HINGE Power Drill NoTE: Make sure hinge leafs are flipped (2) 1/4” - 14 x 5/8” down, when stacking another section on top. 7/16” socket sElF-T aPPING sCREWs Place rollers in hinge tubes of the second Driver section (lock section). With assistance, lift second section and guide rollers into the vertical tracks. align vertical marks in
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u-BaR operator Bracket 11 Tools Needed: NoTE: If installing a trolley type operator, complete this step. If not, skip Power Drill sIDE VIEW OF u-BaR ON TOP this step and continue with step 12. sECTION 7/16” socket TOP sECTION Driver IMPor TANT: WHEN CONNECTING a 1/4” - 20 x 7/8” TROllEy TyPE GaRaGE DOOR OPENER sElF-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 TOP sECTION aNy u-BaRs PROVI
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DOOR WIDTH Top Section NaIl +3-3/8” TO 3-1/2” 12 Tools Needed: Place the top section in the opening and vertically align with lower sections. align Hammer 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
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FlaGaNGlE FlaGaNGlE Attaching horizontal Track to quick Install flagangle 13 kEy Tools Needed: NoTE: If you have fully adjustable slOT flagangle, skip this step and complete 9/16” socket HORIzONTal step 14. TRaCk Ratchet Wrench To install horizontal track, place the 9/16” Wrench quICk INsTall curved end over the top roller. align level TaB key slot of the horizontal track with the quick install tab of the flagangle. Push VERTICal TRaCk curved portion of horizontal track down to loc
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FlaGaNGlE sTuD Attaching horizontal Track Pla TE to Adjustable flagangle 14 NoTE: If quick install flagangles were Tools Needed: installed in step 13, skip this step and continue with step 15. If not, complete this 7/16” socket step. 1/4” - 20 To install horizontal track, place the curved 9/16” socket FlaNGE HEx end over the top roller. align the bottom of NuTs the horizontal track with the vertical track. Ratchet Wrench Hand tighten the horizontal track to the 9/16” Wrench flagangle
