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9800 Series
Torsion Spring
Installation Instructions and Owner’s Manual
Portland Source Plant
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.
© Copyright 2009 Wayne-Dalton Corp. Part No. 326091 REV2 08/03/2009
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WARNING Table of Contents Important Safety Instructions .................................................. 2 READ ThEsE INsTRUCTIONs Package Contents ................................................................... 3 CAREfUlly bEfORE ATTEMPTING Door Section Identification ...................................................... 4 t ools Required ........................................................................ 5 INsTAllATION. If IN qUEsTION AbOUT ANy Of ThE PROCEDUREs, DO Pre-Instal
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NOTE: DEPENDING ON thE DOOR MODEl, SOME P aRtS lIStED WIll NOt bE SuPPlIED If NOt NECESSaR y. REaR SuPPOR tS Package Contents May OR May NOt bE INCluDED WIth yOuR DOOR. DOOR SECtIONS (aS REquIRED) (1) tORSION tubE (2) fully aDjuStablE Rh/lh flaGaNGlES (2) hORIzONtal tRaCkS WIth attaChED hORIzONtal aNGlE Rh/lh DOOR StOP & NaIlS WEathER SEal & NaIlS (1) CENtER bRaCkEt RIGht aND lEft (If INCluDED) (If INCluDED) COuNtERbalaNCE CablES 9800 Series Torsion Spring Installation Instructions and Owne
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Door section Identification t ools 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, #1, #2, #3, and #4 (#4 only on five WaRNING labEl section doors). See view below. the (May bE ON RIGht OR lEft haND SIDE) stamp identifies the stacking sequence of the section. the sequence is always determined
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Tools Required POWER DRIll RatChEt WRENCh PlIERS/WIRE CuttERS t aPE MEaSuRE 1/8”, 3/16” DRIll bItS PhIllIPS hEaD SCREWDRIVER flat 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 SaW hORSES (PaIR) VICE GRIPS (PaIR) VICE ClaMPS Removing An Old Door WARNING If yOuR COuNtERbalaNCE SyStEM IS OthER thaN thOSE MENtIONED, DO NOt attEMPt tO WORk ON It, but haVE a qualIfIED DOOR aGENCy PE
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Torsion spring Removal P1 for standard lift t ools Needed: WARNING tORSION SPRING aSSEMbly Recommended f aIluRE tO uSE aPPROVED tools from WINDING baRS CaN CauSE SPRING page 5 ENERGy tO bE RElEaSED SuDDENly, RESultING IN SEVERE OR fatal INjuR y. WARNING COuNtERbalaNCE SPRING tENSION MuSt bE RElIEVED bEfORE REMOVING aNy WINDING CONE haRDWaRE. a POWERful SPRING RElEaSING It’S ENERGy SuDDENly CaN CauSE SEVERE OR fatal INjuR y. Do not release the torsion spring tension unless you are a
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lOOSEN lOCk COuNtER ® TorqueMaster spring Removal Nut GEaR/ COVER P2 ® a t orqueMaster spring system can be t ools Needed: identified by the end brackets. f or 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.
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® TorqueMaster spring Removal continued... If the counterbalance cable is still taut and t ools Needed: ® the t orqueMaster Spring t ube 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 (f ig. 4 on pr
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REMOVE laG SCREW fROM SafEty CablE (If Extension spring Removal INStallED). REPEat fOR P3 OPPOSItE SIDE. step 1: Raise the door to the fully open t ools 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 RECOMMENDED f aIluRE tO SECuREly t ools Needed: WARNING attaCh a SuItablE MOuNtING P aD tO StR uCtuRally SOuND DOOR hEIGht Recommended fRaMING COulD CauSE SPRINGS tO VIOlENtly tools from lEVEl hEaDER Pull MOuNtING P aD fROM Wall, RESultING page 5 IN SEVERE OR fatal INjuR y. PluMb jaMbS If you just removed your existing door or you are installing a new door, complete all steps in PREPa
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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 INStallatION. IMPORTANT: StaINlESS StEEl OR Pt 2000 COatED laG SCREWS MuSt bE uSED WhEN INStallING CENtER bEaRING bRaCkEtS, END bRaCkEtS, jaMb bRaCkEtS, OPERatOR MOuNtING/SuPPOR t bRaCkEtS aND DISCONNECt bRaCkEtS ON tREatED luMbER (PRESERVatIVE-tREatED). StaINlESS StEEl laG SCREWS aRE NOt NECESSaR y WhEN INStallING PRODuCtS ON uNtREatED
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Installing fully Adjustable fully aDjuStablE Jamb brackets 2 jaMb bRaCkEt t ools Needed: t o attach the bottom jamb bracket, jb-1, locate the first set of quick install None features of the vertical track. align the slot in the jamb bracket with the slot above the quick install features in the vertical track. the long side of the bracket is placed against the track. jaMb bRaCkEt SlOt f asten the jamb bracket finger tight, (1) 1/4”- 20 x 5/8” using (1) 1/4”- 20 x 5/8” carriage bolt Ca
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COuNtERbalaNCE Counterbalance Cables CablE 3 t ools Needed: IMPORTANT: RIGht aND lEft haND IS al WayS DEtERMINED fROM INSIDE thE None GaRaGE lOOkING Out. #1 END hINGE (hINGE tubE) NOTE: f or door section identification see page 4. bOttOM SECtION bOttOM uncoil the counterbalance cables and SECtION slip the loop at the ends of the cables over each milford pin on the bottom ROllERS section. Insert a roller into bottom bracket of the bottom section and insert another roller at #1 end h
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flaGaNGlE vertical Track 5 5/16” x 2” laG SCREWS t ools Needed: IMPORTANT: thE tOPS Of thE VERtICal tRaCkS MuSt bE lEVEl 3/16” Drill bit fROM SIDE tO SIDE. If thE bOttOM SECtION WaS ShIMMED tO lEVEl It. Power Drill thE VERtICal tRaCk ON thE ShIMMED SIDE, MuSt bE RaISED thE hEIGht Of 7/16” Socket thE ShIM. Driver Position the left hand vertical track t ape Measure assembly over the rollers of the bottom VERtICal level section. Make sure the counterbalance tRaCk aSSEMbly cable is loca
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stacking sections 6 t ools Needed: NOTE: f or door section identification see page 4. Power Drill lOCk SECtION NOTE: Make sure hinge leafs are 7/16” Socket Driver flipped down, when stacking another section on top. Place rollers in hinge tubes of the second section (lock section). With assistance, lift the second section and guide rollers into the vertical tracks. keep sections vertically aligned and fasten hinges to connect the sections using 1/4”- 14 x 5/8” self tapping screws. Re
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Top brackets 7 t ools Needed: t o install the l-shaped top brackets, align the bottom holes in the top Power Drill bracket base with the second set of 2ND SEt Of hOlES holes from the end cap. 7/16” Socket fROM bOttOM Driver f asten 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 top bracket slide will be tightened tOP bRaCkEt baSE and adjusted in Step 1
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If NO u-baR IS INStallED Operator bracket OPERatOR OPERatOR bRaCkEt 8 bRaCkEt CENtERED IN thE alIGNED WIth MIDDlE Of tOP SECtION tOP Of SECtION t ools Needed: NOTE: If installing a trolley type operator, complete this step. If not, skip this step Power Drill SIDE VIEW and continue with Step 9. 7/16” Socket IMPORTANT: WhEN CONNECtING a Driver ( 6) 1/4”-20 x 5/8” tROllEy tyPE GaRaGE DOOR OPENER SElf DRIllING (2) Saw horses tO thIS DOOR, a WayNE-DaltON SCREWS OPENER/tROllEy bRaCkEt MuS
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Top section 9 Place the top section in the opening t ools Needed: DOOR WIDth and vertically align with lower sections. +3-3/8” tO 3-1/2” hammer t emporarily secure the top section by t ape Measure driving a nail in the header near the center of the door and bending it over Power Drill the top section. 7/16” Socket Driver Now flip up hinge leaf against section, fastening center hinges first, and end hinges last. (Refer to Step 6). When installing a door with a torsion counterbalance syst
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hORIzONtal Attaching horizontal Track to Adjustable flaGaNGlE tRaCk flagangle 10 (2) 1/4”- 20 x 5/8” t ools Needed: t o install horizontal track, place the curved end over CaRRIaGE bOltS the top roller. align the bottom of the horizontal track 9/16” Socket with the vertical track. hand tighten the horizontal track to the flagangle with (2) 1/4”- 20 x 5/8” carriage 7/16” Socket bolts and (2) 1/4”- 20 flange hex nuts. Ratchet Wrench level the horizontal track assembly and bolt the horizont
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Torsion End bearing brackets lEft END bEaRING bRaCkEt 12 t ools Needed: End bearing brackets are right and left. using the upper slots in the end bearing Power Drill bracket, position above the flagangle and secure the end bearing bracket to 7/16” Socket the horizontal angle using Driver (2) 3/8”- 16 x 3/4” hex head bolts and 9/16” Socket (2) 3/8”- 16 nuts. hORIzONtal aNGlE Once the bracket is secured to the Ratchet Wrench horizontal angle, secure the top of the 9/16” Wrench end bearin
