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9800 Series (4 Section)
®
TorqueMaster - Single and Double Spring(s)
Installation Instructions and Owner’s Manual
IMPORTANT NOTICE!
Read these instructions carefully before attempting
installation. If in question about any of the proce-
Wayne-Dalton, a Division of
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 Overhe
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WARNING TO AVOID POSSIBLE Table of Contents 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 Package Contents NECEssaR y. REaR suPPORTs May OR May NOT BE INCluDED WITH yOuR DOOR. DOOR sECTIONs (as REquIRED) (1) OPERaTOR BRaCkET ® (1)TORquEMasTER sPRING TuBE (2) HORIzONTal TRaCk RH/lH (2) quICk INsT all RH/lH (2) Fully aDjusT aBlE RH/lH FlaGaNGlE (as REquIRED) FlaGaNGlE (as REquIRED) DOOR sTOP & NaIls WEaTHER sEal & NaIls (2) HORIzONTal aNGlE (IF INCluDED) RIGHT aND lEFT CaBlE ® (IF INCluDED) (80” OR 9
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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 #3 the top of each section (except top section) and the hinges are stamped for identification, #1, #2, #3, and #4 (#4 WaRNING laBEl only on five section doors). see view (May BE ON RIGHT OR lEFT HaND sIDE) below. The stamp identifies the stacking sequence of the section. The sequence is always determined b
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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 7/16”, 1/2”, 9/16” 3/8”, 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 HaVE a qua
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Torsion Spring Removal P1 for Standard Lift Tools Needed: WARNING TORsION sPRING assEMBly approved FaIluRE TO usE aPPROVED Winding Bars WINDING BaRs CaN CausE sPRING ENERGy TO BE RElEasED suDDENly, REsul TING IN sEVERE 3/8” Wrench OR FaTal INjuR y. WARNING Vice Clamp COuNTERBalaNCE sPRING TENsION MusT BE RElIEVED Recommended BEFORE REMOVING aNy WINDING CONE tools from HaRDWaRE. a POWERFul sPRING page 5 RElEasING IT’s ENERGy suDDENly CaN CausE sEVERE OR F aTal INjuR y. Do not release
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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... If the counterbalance cable is still taut and Tools Needed: ® the TorqueMaster spring Tube is difficult to rotate, that is an indication that spring Recommended tension still exists on the left hand spring. tools from Repeat steps 1 and 2 for releasing spring page 5 tension on the left hand side. Step 4: using a flat tip screwdriver, pry REMOVE TOP the counter gear and counter cover laG sCREW from the right hand end bracket (Fig. 4 on previou
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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 If you just removed your existing door or you are installing a Tools Needed: new door, complete all steps in PREPaRING THE OPENING. Recommended To ensure secure mounting of track brackets, side DOOR HEIGHT tools from and center brackets, or steel angles to new or retro-fit lEVEl HEaDER page 5 construction, it is recommended to follow the procedures outlined in DasMa Technica
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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 T
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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 NOTE: If you have quick install jamb Tools Needed: brackets, skip this step and complete step 5. None The bottom jamb bracket is always the shortest bracket included with your sT-0 sT-1 door. If three jamb brackets are included with you door, the second bracket up HOlE/slOT is the middle bracket in height. The jaMB PaTTERN top jamb bracket is the tallest bracket BRaCkET included. 1/4”-20 x To attach the bott
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Installing q.I. Jamb Brackets 5 Tools Needed: NOTE: If you have fully adjustable jamb brackets, skip this step and complete None step 6. Measure the length of the vertical tracks. using the jamb bracket schedule, l EFT sIDE sHOWN RIGHT sIDE sHOWN determine the placement of the jamb TWIsTlOCk TaB brackets for your door height and track 3RD sET HOlEs type. To install the jamb brackets, align the twistlock tab on the quick install jamb bracket with the quick install TOP feature in the t
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Bottom Section 7 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 section. WEaTHER sEal lEVEl BOTTOM sECTION WOODEN sHIMs (IF NECEssaR y) VERITCal TRaCk CaBlE Vertical Track BOTTOM sECTION FlaGaNGlE DRuM 8 Tools Needed: IMPORTANT: THE TOPs OF THE 5/16” x 1-5/8”
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Stacking Sections 9 Tools Needed: NOTE: For door section identification see 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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Top Brackets 10 2ND sET OF HOlEs FROM BOTTOM To install the l-shaped top brackets, align Tools Needed: the bottom holes in the top bracket base Power Drill with the second set of holes from the 7/16” socket endcap. Driver Fasten 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
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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 this step and continue with step 12. 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,
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Top Section 12 Place the top section in the opening Tools Needed: DOOR WIDTH and vertically align with lower sections. +3-3/8” TO 3-1/2” Hammer 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 firs
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Attaching horizontal Track to FlaGaNGlE HORIzONTal quick Install flagangle TRaCk 13 Tools Needed: NOTE: If you have fully adjustable flagangle, skip this step and complete kEy slOT 9/16” socket step 14. Ratchet Wrench quICk 9/16” Wrench To install horizontal track, place the INsTall curved end over the top roller. align TaB level key slot of the horizontal track with the quick install tab of the flagangle. Push VERTICal curved portion of horizontal track down TRaCk to lock in place
