9800 Series (3 Section) Torsion Spring Installation Instructions and Owner’s Manual Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.wayne-dalton.com Copyright 2009 Wayne-Dalton Corp. 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. Part No.
Table of Contents Important Safety Instructions................................................... 2 Package Contents.................................................................... 3 Door Section Identification....................................................... 4 Tools Required......................................................................... 5 Pre-Installation...................................................................5-10 Removing The Old Door........................................
Package Contents PRE-INSTALLATION NOTE: Depending on the door model, some parts listed will not be supplied if not necessary. rear supports may or may not be included with your door. DOOR SectionS (as required) (1) operator bracket (1) Torsion Tube (2) Fully Adjustable RH/LH Flagangle (as required) (2) Quick Install RH/LH Flagangle (as required) Right & left Drums RH/LH Torsion springs (as required) Right and left cable assemblies Q.I.
Door Section Identification Tools Needed: NOTE: This provides an alternative method for identifying your door sections/stacking position. Top Section The section side view illustration shows the end hinge profile of all the sections, and can also be used in conjunction with identifying each sections. The bottom section can be identified by a #1 single end hinge, the factory attached bottom astragal, or by the bottom bracket warning labels on each end stile.
Power Drill Ratchet Wrench Pliers/Wire Cutters Tape Measure Phillips Head Screwdriver Flat Tip Screwdriver Pencil Needle Nose Pliers 7/16”, 1/2”, 9/16” Sockets 7/16” Socket Driver 3/8”, 7/16”, 1/2”, 9/16” Wrenches Safety Glasses Hammer vice grips (PAIR) vice clamps saw horses (pair) PRE-INSTALLATION Tools Required 1/8”, 3/16” Drill Bits gLOVES Step Ladder Removing An Old Door WARNING If your counterbalance system is other than those mentioned IN SECTIONS P1, P2 AND P3, do not attempt t
P1 Tools Needed: Approved Winding Bars 3/8” Wrench Vice Clamp Recommended tools from page 5 Torsion Spring Removal For Standard Lift WARNING TORSION SPRING ASSEMBLY Failure to use approved winding bars can cause spring energy to be released suddenly, resulting in severe or fatal injury. WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.
Tools Needed: Recommended tools from page 5 loosen lock nut counter gear/ cover A TorqueMaster® spring system can be identified by the end brackets. For single spring applications, the right hand end bracket will always have a drive gear, counter gear, counter cover, and a winding bolt head. The left hand end bracket will have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged.
TorqueMaster® Spring Removal continued... Tools Needed: Recommended tools from page 5 If the counterbalance cable is still taut and the TorqueMaster® Spring Tube is difficult to rotate, that is an indication that spring tension still exists on the left hand spring. Repeat Steps 1 and 2 for releasing spring tension on the left hand side. Step 4: Using a flat tip screwdriver, pry the counter gear and counter cover from the right hand end bracket (Fig. 4 on previous page).
Tools Needed: Recommended tools from page 5 Extension Spring Removal Step 1: Raise the door to the fully open position and place vice clamps to the back legs of both vertical tracks, below the bottom rollers to prevent the door from falling. By opening the door you release most of the spring tension. Carefully unfasten the S-hook from the horizontal angle. Remove cable, sheave and extension spring. Repeat for the other side. If safety cables are running through the extension springs, remove them also.
P5 Tools Needed: Recommended tools from page 5 10 Preparing the Opening WARNING FAILURE TO SECURELY ATTACH A SUITABLE MOUNTING PAD TO STRUCTURALLY SOUND FRAMING COULD CAUSE SPRINGS TO VIOLENTLY PULL MOUNTING PAD FROM WALL, RESULTING IN SEVERE OR FATAL INJURY. If you just removed your existing door or you are installing a new door, complete all steps in PREPARING THE OPENING.
Installation IMPORTANT: Read instructions titled “p4” “Removing the old door” on page 9 and “p5” “PREPARING THE OPENING” on page 10 before attempting door installation. IMPORTANT: Stainless steel or PT 2000 coated lag screws MUST be used when installing center bearing brackets, end brackets, jamb brackets, operator mounting/support brackets and disconnect brackets on treated lumber (preservative-treated). Stainless steel lag screws are NOT necessary when installing products on un-treated lumber.
2 Tools Needed: None Attaching Fully Adjustable Flagangle to Vertical Track Fully Adjustable flagangle NOTE: If quick install flagangle was installed in Step 1, skip this step and continue with Step 3. If not, complete this step. 1/4”- 20 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 included) and (2) 1/4” - 20 flange hex nuts. Repeat for other side.
Tools Needed: None fully adjustable jamb brackets NOTE: If you have quick install jamb brackets, skip this step and complete Step 5. The bottom jamb bracket is always the shortest bracket included with your door. If three jamb brackets are included with you door, the second bracket is the middle bracket in height. The top jamb bracket is the tallest bracket included. To attach the bottom jamb bracket, locate the lower hole/slot pattern of the vertical track.
5 Tools Needed: None Installing Q.I. Jamb Brackets NOTE: If you have fully adjustable jamb brackets, skip this step and complete Step 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.
7 Tools Needed: Level Bottom Section door opening Before installing the bottom section, the weather seal (may not be included) 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.
9 Tools Needed: Power Drill 7/16” Socket Driver Stacking Sections NOTE: For door section identification see page 4. LOCK SECTION NOTE: Make sure hinge leafs are flipped 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. IMPORTANT: Push & hold the hinge leafs against section while securing with 1/4” - 14 x 5/8” self-tapping screws.
10 Tools Needed: Power Drill 7/16” Socket Driver Top Brackets To install the L-shaped top brackets, align the bottom holes in the top bracket base with the second set of holes from the endcap. 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 bracket slide. Repeat for other side.
11 Tools Needed: Power Drill 7/16” Socket Driver u-bar Operator Bracket NOTE: If installing a trolley type operator, complete this step. If not, skip this step and continue with step 12. IMPORTANT: When installing a trolley type operator on 9800 door, a Wayne-Dalton trolley bracket must be securely attached to the top section.
Tools Needed: Hammer Top Section Place the top section in the opening and vertically align with lower sections. 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 tight against section, and fasten center hinges first, and end hinges last. (Refer to Step 9).
13 Tools Needed: 9/16” Socket Ratchet Wrench 9/16” Wrench Level Attaching Horizontal Track to Quick Install Flagangle NOTE: If you have fully adjustable flagangle, skip this step and complete Step 14. To install horizontal track, place the curved end over the top roller. Align key slot of the horizontal track with the quick install tab of the flagangle. Push curved portion of horizontal track down to lock in place.
14 Tools Needed: 9/16” Socket 7/16” Socket Ratchet Wrench 9/16” Wrench Level Flat tip Screwdriver Attaching Horizontal Track to Adjustable Flagangle NOTE: If quick install flagangles were installed in Step 13, skip this step and continue with Step 15. If not, complete this step. flagangle Stud plate To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track with the vertical track.
15 Tools Needed: Step Ladder Power Drill Ratchet Wrench 7/16” Socket Driver 9/16” Socket Driver 9/16” Wrench Torsion End Bearing Brackets End bearing brackets are right and left hand. Break the end bearing brackets apart. Starting on the left hand side and using the upper slots in the end bearing bracket, position above the flagangle and secure the end bearing bracket to the horizontal angle using (2) 3/8”-16 x 3/4” truss head bolts and (2) 3/8”-16 nuts.
Tools Needed: none NOTE: Right and left hand is always determined from inside the building looking out. NOTE: Identify the springs provided as either right hand wound (red winding cone), which goes on the LEFT HAND SIDE or left hand wound (black winding cone), which goes on the RIGHT HAND SIDE. Facing the inside of the door, lay the torsion tube on the floor. Lay the spring with the black color coded winding cone and the black color coded cable drum, at the right hand end of the tube.
18 Tools Needed: Center bearing bracket Nylon Center Bushing Slide the nylon center bushing into the stationary spring cone at the end of the spring and align the stationary spring cone(s) with the holes in the center bearing bracket. Secure the spring(s) to the center bearing bracket with (2) 3/8”-16 x 1-1/2” hex head bolts and 3/8”-16 nuts. IMPORTANT: Springs under tension can be dangerous.
Tools Needed: Vice Grips 3/8” Wrench Release the vice grips from the ends of the cables and thread the counterbalance cables around the back side of the left cable drum and verify that there is no cable obstructions. Hook the cables into the drums. Slide the left hand cable drum against the left hand end bearing 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).
21 Tools Needed: Power Drill 3/16” Drill Bit 7/16” Socket Driver Phillips Head Screwdriver Winding Torsion Spring(s) Position a ladder slightly to the side of spring so that the winding cone is easily accessible, yet your body is not in direct line with the winding bars. Check the label attached to the spring warning tag for the required number of complete turns to balance your door.
22 Tools Needed: Ratchet Wrench 1/2” Socket 1/2” Wrench Vice Clamps Rear Support DOOR IN THE UP POSITION WARNING Keep horizontal track parallel and within 3/4” maximum of door edge, otherwise door could fall, resulting in severe injury or death. Raise the door until the top section and half of the next section are in a horizontal position. Do not raise door any further since rear of horizontal track is not yet supported.
Rear Support Continued... Tools Needed: WARNING Prior to winding or making adjustments to the springs, ensure you’re winding in the proper direction as stated in the Installation Instructions. Otherwise the spring fittings may release from spring if not wound in the proper direction and could result in severe or fatal injury. To adjust spring tension, fully close door. Apply locking pliers to track above third roller. Insert a winding bar into the winding cone.
� Tools Needed: Power Drill 7/16” Socket Driver 1/8” Side Lock Install the side lock on the second section of the door. Secure the lock to the section with (4) 1/4”- 20 x 11/16” self drilling screws. Square the lock assembly with the door section and align with the square hole in the vertical track. The side lock should be spaced in approximately 1/8” from the section edge. IMPORTANT: side locks must be removed or made inoperative in the unlocked position if an operator is installed on the door.
� Tools Needed: Trolley Operator WARNING OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR. FAILURE TO ADJUST OPERATOR, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY. IF YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM, THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED.
Cleaning Your Steel And Fiberglass Garage Door IMPORTANT: DO NOT USE A PRESSURE WASHER ON GARAGE DOOR! While factory-applied finishes on garage doors are durable, it is desirable to clean them on a routine basis. Some discoloration of the finish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a result of direct exposure to sunlight. Cleaning the door will generally restore the appearance of the finish.
Steel Preparation For Painting Steel (Surface Preparation for Painting) Wax on the surface must be removed or paint peeling/flaking will result. To remove this wax, it will be necessary to lightly scuff the surface with a fine steel wool pad, saturated with soapy water. A final wipe and rinse should be done with clean water only, to remove any loose particles and any soapy film residue.
Subject to the terms and conditions contained in this Lifetime Limited Warranty, Wayne-Dalton Corp. (“Manufacturer”) warrants the sections of the door for as long as you own the door with the exception of the items that follow which is described at the top of this page.
Thank you for your purchase www.wayne-dalton.com “Covered by one or more of the following Patents; 5,408,724; 5,409,051; 5,419,010; 5,495,640; 5,522,446; 5,562,141; 5,566,740; 5,568,672; 5,718,533; 6,019,269; 6,089,304; 6,644,378; 6,374,567; 6,561,256; 6,527,037; 6,640,872; 6,672,362; 6,725,898; 6,843,300; 6,915,573; 6,951,237; 7,014,386; 7,036,548; 7,059,380; 7,121,317; 7,128,123; 7,134,471; 7,134,472; 7,219,392; 7,254,868.
