Wayne-Dalton 9800 User Manual
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
Table of Contents
Important Safety Instructions .................................................. 2
Package Contents ................................................................... 3
Door Section Identification ...................................................... 4
Tools Required ........................................................................ 5
WARNING
READ THESE INSTRUCTIONS
CAREFULLY BEFORE ATTEMPTING
INSTALLATION. IF IN QUESTION
Pre-Installation ..................................................................5-10
Removing The Old Door .......................................5-9
Preparing The Opening ......................................... 10
Installation ......................................................................11-26
Optional Installations .......................................................27-28
Side Lock .............................................................27
Pull Rope .............................................................. 27
Trolley Operator .................................................... 28
Maintenance ....................................................................29-30
Cleaning ............................................................... 29
Painting Instructions ........................................29-30
Warranty ............................................................................... 31
Customer Service Number .................................................... 32
Definition of key words used in this manual:
WARNING
INDICATES A POTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, COULD
RESULT IN SEVERE OR FATAL INJURY.
CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT
FROM FAILURE TO FOLLOW INSTRUCTIONS.
IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER
DOOR OPERATION.
NOTE: Information assuring proper installation of the door.
ABOUT ANY OF THE PROCEDURES, DO
NOT PERFORM THE WORK. INSTEAD,
HAVE A QUALIFIED DOOR AGENCY DO
THE INSTALLATION OR REPAIRS.
1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.
2. Wear protective gloves during installation to avoid possible
cuts from sharp metal edges.
3. It is always recommended to wear eye protection when using
tools, otherwise eye injury could result.
4. Avoid installing your new door on windy days. Door could
fall during the installation causing severe or fatal injury.
5. Doors 12’-0” wide and wider should be installed by two
persons, to avoid possible injury.
6. Operate door ONLY when it is properly adjusted and free from
obstructions.
7. If a door becomes hard to operate, inoperative or is damaged,
immediately have necessary adjustments and/or repairs
made by a trained door system technician using proper tools
and instructions.
8. DO NOT stand or walk under a moving door, or permit
anybody to stand or walk under an electrically operated door.
9. DO NOT place fingers or hands into open section joints when
closing a door. Use lift handles/gripping points when operating
door manually.
10. DO NOT permit children to operate garage door or door
controls. Severe or fatal injury could result, should the child
become entrapped between the door and the floor.
11. Due to constant extreme spring tension, DO NOT attempt any
adjustment, repair or alteration to any part of the door,
especially to springs, spring brackets, bottom corner brackets,
red colored fasteners, cables or supports. To avoid possible
severe or fatal injury, have any such work performed
by a trained door systems technician using proper tools and
instructions.
12. On electrically operated doors, pull down ropes must be
removed and locks must be removed or made inoperative in
the open (unlocked) position.
13. Top section of door may need to be reinforced when attaching
an electric opener. Check door and/or opener manufacturer’s
instructions.
14. VISUALLY inspect door and hardware monthly for worn and or
broken parts. Check to ensure door operates freely.
15. Test electric opener’s safety features monthly, following
opener manufacturer’s instructions.
16. NEVER hang tools, bicycles, hoses, clothing or anything else
from horizontal tracks. Track systems are not intended or
designed to support extra weight.
After installation is complete, fasten this manual
near garage door.
© Copyright 2006 Wayne-Dalton Corp. Part No. 326091 NEW 05/08/2006
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, ha ve a q uali fied d oor a genc y
do the installation or repairs.
9800 Series
(2) FULLY ADJUSTABLE
RH/LH FLAGANGLES
Package Contents
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) TORSION TUBE
(2) HORIZONTAL TRACKS WITH ATTACHED HORIZONTAL ANGLE RH/LH
RIGHT AND LEFT
COUNTERBALANCE CABLES
RH/LH TORSION
SPRINGS (AS REQUIRED)
ROLLERS
(AS REQUIRED)
1/4”- 20 FLANGE HEX
NUTS (AS REQUIRED)
DOOR STOP & NAILS
(IF INCLUDED)
MANUAL (1) CENTER BRACKET
RIGHT & LEFT
DRUMS
(1) OPERATOR BRACKET (2) TOP BRACKET
SLIDES
(2) 3/8”- 16
HEX NUTS
1/4”- 14 X 5/8” SELF TAPPING
SCREWS (AS REQUIRED)
WEATHER SEAL & NAILS
(IF INCLUDED)
RIGHT & LEFT
END BEARING BRACKETS
(2) TOP BRACKET
BASES
1/4”- 20 X 5/8” CARRIAGE
BOLTS (AS REQUIRED)
(1) CENTER BRACKET
JAMB BRACKETS
(AS REQUIRED)
(2) 3/8”- 16 X 3/4”
HEX HEAD BOLTS
BUSHING
RH/LH TRACKS
SCREW EYE & PULL
ROPE (IF INCLUDED)
1/4”- 20 X 7/8” SELF DRILLING
SCREWS (AS REQUIRED)
(2) VERTICAL
(2) 3/8”- 16 X 1-1/2” HEX HEAD BOLT 5/16” X 2” TAMPER RESISTANT LAG
5/16” X 2” HEX HEAD LAG SCREWS (AS REQUIRED)
SCREW (AS REQUIRED)
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3
Door Section Identification
Tools Needed:
NOTE: This provides an alternative method
for identifying your door sections/stacking
position.
Hinges are always pre-attached at the top
of each section (except top section) and
the hinges are stamped for identification,
#1, #2, #3, and #4 (#4 only on five
section doors). See view below. The
stamp identifies the stacking sequence
of the section. The sequence is always
determined by #1 being the bottom
section to #3 or #4 being the highest
intermediate section. See views to the
right. If the stamp on the end hinge is
illegible, refer to the section side view
illustration to the right.
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 #1 end hinges, the factory attached
bottom astragal and the bottom bracket
warning labels on each end stile.
The LOCK SECTION can be identified by a
#2 end hinge.
The INTERMEDIATE SECTION can be
identified by #3 end hinges. The section
will have a warning label attached to
either the right or left hand end stile.
#3
#2
#1
ASTRAGAL
TOP SECTION
WARNING LABEL
(MAY BE ON RIGHT OR LEFT HAND SIDE)
INTERMEDIATE SECTION
LOCK SECTION
BOTTOM BRACKET
WARNING LABELS
BOTTOM SECTION
SECTION SIDE VIEW
1 3/8”
1 1/8”
7/8”
NOTE: #4 End hinges are used on the
fourth section of five section doors.
U-BAR
The TOP SECTION can be identified with
no pre-installed end or center hinges and
#3 END
HINGE
#2 END
HINGE
U-bar attached to the top section.
TOP
TYPICAL HINGE STAMPING LOCATION
4
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INT.
ASTRAGAL
#1 END
HINGE
BOT.LOCK
BOTTOM
BRACKET
Tools Required
POWER DRILL RATCHET WRENCH PLIERS/WIRE CUTTERS
PHILLIPS HEAD SCREWDRIVER PENCIL
7/16”, 1/2”, 9/16”
SOCKETS
HAMMER
FLAT TIP SCREWDRIVER
7/16” SOCKET DRIVER
VICE GRIPS (PAIR) VICE CLAMPS
3/8”, 7/16”, 1/2”, 9/16”
WRENCHES
Removing An Old Door
TAPE MEASURE
NEEDLE NOSE PLIERS
SAFETY GLASSES
SAW HORSES (PAIR)
1/8”, 3/16” DRILL BITS
GLOVES
STEP LADDER
WARNING
IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED, DO NOT ATTEMPT TO WORK ON IT, BUT
HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
WARNING
DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO
PREVENT UNINTENDED DOOR OPERATION. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
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.
WARNING
IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS, OR SEVERE INJURY COULD RESULT
WARNING
REMOVING AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSTRUCTIONS ON PAGES 6-10 “REMOVING AN
OLD DOOR/PREPARING THE OPENING” CAREFULLY, OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
If you have an existing door, follow the instructions to identify which counterbalance removal is necessary. The process of removing
an existing door begins by identifying it’s counterbalance system. If you are not removing an existing door, proceed to PREPARING THE
OPENING on page 10. Generally, you will find three (3) types of counterbalance systems: Extension Spring, Wayne-Dalton® exclusive
TorqueMaster® and Torsion counterbalance system, see pages 6-9.
For more technical information regarding the opening preparation, installation and use of your garage door and opener, you can go to
www.dasma.com and click on Publications and then Technical Data Sheet.
Please Do Not Return This Product To The Store. Call Us Directly! Our Trained Technicians Will Answer Your Questions and/or Ship Any Parts
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5
P1
Torsion Spring Removal
For Standard Lift
Tools Needed:
Recommended
tools from
page 5
WARNING
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.
Do not release the torsion spring
tension unless you are a qualified and
experienced door technician. Instead have
a professional door agency release the
tension.
Step 1: Close the door and place vice
clamps on the back legs of both vertical
tracks, above the third roller to prevent the
door from lifting as you unwind the springs.
Use only approved winding bars available
from your dealer. Do not use undersized
steel rods, screw drivers or anything else
to unwind the springs. Position the ladder
just off to the side of the winding cone.
The winding cone should be easy to reach
without putting your body directly in front
of it.
TORSION SPRING ASSEMBLY
WINDING CONE
APPROVED WINDING BAR
Step 2: Insert a winding bar into one of the
holes in the winding cone. Exert upward
pressure. Using caution, loosen the two
(2) set screws in the winding cone. Be
prepared to support the full torsional force
of the spring when the set screws are
loosened.
Step 3: Once set screws are loose, slowly
and carefully lower the winding rod until
it rests against the door. Insert other
winding bar into the upper hole. Push up
and remove lower bar. Carefully lower
upper winding bar, 1/4 turns at a time until
it rests against the door. Repeat process
until all tension is relieved. If your door
is equipped with two (2) torsion springs,
follow the same procedure to relieve
tension on the second spring.
Step 4: Remove vice clamps from tracks,
unbolt torsion shaft assembly and remove
from work area.
NOTE: Continue with “P4” on page 9 after
completing this step.
6
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SET SCREWS
FIRMLY HOLD WINDING BARS AND
CAUTIOUSLY LOOSEN SET SCREWS
P2
Tools Needed:
Recommended
tools from
page 5
TorqueMaster® Spring Removal
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
LOOSEN LOCK
NUT
COUNTER
GEAR/ COVER
RIGHT HAND
END BRACKET
bolt head. The hole for the winding bolt
head will be plugged.
For double springs, both the right hand
and left hand end brackets will always
have a drive gear, counter gear, counter
cover and a winding bolt head.
IMPORTANT: RIGHT AND LEFT HAND IS
ALWAYS DETERMINED FROM INSIDE THE
BUILDING LOOKING OUT.
Step 1: If you have a black counter cover:
Fig. 1
PLACE MARK ON END BRACKET
AND DRIVE GEAR TOOTH
BEFORE UNWINDING SPRINGS
END BRACKET
RIGHT HAND
WINDING BOLT HEAD
Place a mark on the drive gear tooth and an
adjacent mark on the right hand end bracket
(Fig. 1). Loosen the lock nut using a 7/16”
wrench and continue with step 2.
If you have a gray counter cover: Loosen
the lock nut using a 7/16” wrench and
ELECTRIC DRILL
WITH 7/16” HEX
DRIVER (DO NOT
USE IMPACT
continue with step 2.
Step 2: Using an electric drill (High
torque / gear reduced to 1300 rpm
preferred) with a 7/16” hex head driver,
unwind the right hand winding bolt head
counterclockwise (Fig. 2) and count the
number of turns the mark on the drive
gear passes the adjacent mark on the end
bracket. Referencing the chart below, by
RIGHT HAND
CABLE DRUM
Fig. 2
door height, stop unwinding the spring
once the counted turns have reached the
listed number of turns.
6’-0” Door Height = 14 turns
TORQUEMASTER®
SPRING TUBE
6’-3” Door Height = 14 1/2 turns
6’-5” Door Height = 15 turns
6’-6” Door Height = 15 turns
6’-8” Door Height = 15 1/2 turns
6’-9” Door Height = 15 1/2 turns
7’-0” Door Height = 16 turns
CHECK CABLE
7’-3” Door Height = 16 1/2 turns
7’-6” Door Height = 17 turns
7’-9” Door Height = 17 1/2 turns
8’-0” Door Height = 18 turns
CAUTION:
DO NOT USE IMPACT GUN TO
Fig. 3
UNWIND SPRINGS.
IMPORTANT: DO NOT REFERENCE THE
COUNTER COVER WHEN COUNTING THE
NUMBER OF TURNS BEING UNWOUND
ON TH E SP R I N G, BU T F O L L O W THE
INSTRUCTIONS ABOVE.
Step 3: Verify that spring tension has been
released by pulling the counterbalance
cable on the right hand cable drum away
from the header (Fig. 3). If spring tension
has been released, the cable will be loose.
In addition, the TorqueMaster® Spring
PRY COUNTER GEAR
AND COUNTER COVER
FROM END BRACKET
USING FLAT TIP
SCREWDRIVER
Tube should be free to rotate in either
direction.
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Fig. 4
PRE-INSTALLATION
GUN)
TENSION
COUNTER
GEAR
COUNTER
COVER
7
TorqueMaster® Spring
Removal continued...
Tools Needed:
If the counterbalance cable is still taut and
the TorqueMaster® Spring Tube is difficult
Recommended
tools from
page 5
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). Discard the counter
REMOVE TOP
LAG SCREW
Fig. 5
gear and counter cover. On double spring
applications, repeat for left hand side.
Step 5: Remove the upper 5/16” x
1-5/8” lag screw from the right hand end
USE LOCKING PLIERS
TO HOLD END BRACKET
bracket (Fig. 5). Attach locking pliers to
the upper portion of the end bracket and
hold the housing steady while removing
the lower 5/16” x 1-5/8” lag screw and
PHILLIPS HEAD
#10 x 1/2” phillips head screw from the
end bracket (Fig. 6).
Step 6: Holding the right hand end
bracket steady with locking pliers,
carefully pry the end bracket and drive
gear off the winding shaft using a flat tip
screwdriver (Fig. 7).
CAUTION: THE WINDING SHAFT MAY
REMOVE
BOTTOM LAG
SCREW
Fig. 6
ROTATE WHEN REMOVING THE END
BRACKET AND DRIVE GEAR.
Step 7: Repeat Step 4 for the left hand
side. Holding the left hand end bracket
steady with locking pliers, carefully pry
the end bracket off the winding shaft
using a flat tip screwdriver (Fig. 7).
Step 8: Remove the two (2) lag bolts
attaching the center bracket assembly to
the header board (Fig. 8).
Step 9: Lift the right hand side of the
TorqueMaster
®
Spring Tube and slide the
PRY END BRACKET FROM WINDING
SHAFT USING A FLAT TIP SCREW
DRIVER AND LOCKING PLIERS
cable drum off. Realign the groove in the
winding shaft with the round notch in the
flagangle and drape the counterbalance
cable with drum over the flagangle. Lift
the left hand side of the TorqueMaster®
Spring Tube and slide the cable drum
and winding shaft off (Fig. 9). Drape the
counterbalance cable with drum over the
CENTER
BRACKET
ASSEMBLY
Fig. 7
REMOVE CABLE DRUM AND
WINDING SHAFT
flagangle. Lift the TorqueMaster® spring
assembly off the flagangles and out of
the doorway. Unhook the counterbalance
cables from the bottom brackets and
remove all parts from the work area.
NOTE: The cable drums may be difficult to
remove. If so, twist the cable drum to aid
in removal.
NOTE: Continue with “P4” on page 9 after
completing this step.
8
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(2) 5/16” X 1-5/8”
HEX HEAD LAG
SCREWS
Fig. 8
DRAPE CABLE ACROSS
TOP OF FLAGANGLE
Fig. 9
REMOVE #10
SCREW
HOLD THE
END BRACKET
STEADY WITH
LOCKING PLIERS
LIFT
TORQUEMASTER®
SPRING TUBE
OFF FLAGANGLE
P3
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. Remove parts
from work area.
Step 2: Holding door in the open position,
remove the vice clamps, be prepared
to support the entire weight of the door.
Garage doors can weigh 200-400 pounds.
With assistance, carefully lower the door, by
grasping the door firmly by it’s lift handles.
Do not place fingers or hands near joints,
between sections, or between bottom of
door and floor. Otherwise, severe injury
could result.
REMOVE LAG SCREW
FROM SAFETY CABLE (IF
INSTALLED). REPEAT FOR
OPPOSITE SIDE.
BOTTOM SECTION
(DOOR OPEN)
PRE-INSTALLATION
CAREFULLY REMOVE “S”
HOOK AND COUNTERBALANCE
CABLE (REPEAT FOR THE
OPPOSITE SIDE)
HORIZONTAL ANGLE
P4
Tools Needed:
Recommended
tools from
page 5
NOTE: Continue with “P4” on page 9 after
completing this step.
Removing the Old Door
Having removed the counterbalance
system, the door can now be
disassembled.
Start by first removing the top row of
hinges.
With assistance, hold the top section to
keep it from falling and remove the
top brackets. With assistance, lift the top
section out of the opening and remove
it from the work area. Repeat for all
remaining sections.
After door is disassembled, unbolt both
track assemblies from the jambs and
remove all material from the work area.
You can neatly dispose of the old door by
placing it in the carton of your new door.
TOP BRACKET
HORIZONTAL TRACK
HINGES
Clean up area and complete “Preparing
the Opening” “P5” on page 10 before
installing the new door.
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9
P5
Tools Needed:
Recommended
tools from
page 5
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.
HEADER BOARD
2” X 6” LUMBER
RECOMMENDED
PLUMB JAMBS
SUITABLE MOUNTING
SURFACE 2” X 6”
LUMBER MINIMUM
DOOR HEIGHT
LEVEL HEADER
For detailed technical information regarding the opening
preparation, refer to the DASMA Technical Data Sheet TDS #161
“Connecting Garage Door Jambs to Building Framing” at www.
dasma.com.
The inside of your garage door opening should be framed with
wood jambs and header. It is recommended that 2” x 6” lumber
be used. The jambs must be plumb and the header level. The
jambs should extend a minimum of 14” (356 mm) above the top
of the opening for Torsion
applications, the jambs should extend to the ceiling height.
Minimum side clearance required, from the opening to the wall, is
3-1/2” (89 mm).
IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING
SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE
REPLACED.
The jambs and header must be securely fastened to sound framing
members. Do not place jambs and header over drywall, paneling,
etc. Heads of fasteners must be flush or below jamb and header
surface, so they do not interfere with installation or operation of
new door.
springs applications, a suitable mounting surface must be
Torsion
firmly attached to the wall, above the header at the center of the
opening.
The mounting surface must be 2” x 6” lumber minimum (Select
southern yellow pine lumber. Do not use lumber marked as sprucepine-fur or SPF).
The mounting surface must be securely attached to block or
concrete wall with four (4) 3/8” masonry anchors or four
(4) 5/16” x 4” lag screws for a wood structure.
NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid
splitting the lumber. Do not attach the mounting surface with
nails.
WEATHER SEAL / DOOR STOP: Cut weather seal or door stop (may
not be included) to fit the jambs and header.
Align the edge of the weather seal or door stop an 1/8” to 1/4”
inside the edge of the opening. Temporarily nail approximately
12” to 18” apart, the weather seal apart. or door stop to the
jambs to keep the bottom section from falling out of the opening
during installation.
NOTE: Do not permanently attach weather seal or door stop to the
jambs at this time. Permanent installation will be done in Step 19.
HEADROOM REQUIREMENT: Headroom is defined as the space
needed above the top of the door for tracks, springs, etc. to allow
the door to open properly. If the door is to be motor operated, 2-1/2”
(64 mm) of additional headroom is required.
BACKROOM REQUIREMENT: Backroom is defined as the distance
needed from the opening back into the garage to allow the door
to open fully.
springs applications. For low headroom
DOOR
WIDTH
HEADROOM
HEADER
WEATHER SEAL
JAMB
1/8” TO 1/4”
JAMB
FULLY ADJUSTABLE TRACK
DOOR
STOP
DOOR
SECTION
JAMB
JAMB
HEADROOM REQUIREMENT
TRACK TYPE TorqueMaster
14” Radius track 12”
BACKROOM REQUIREMENT
DOOR HEIGHT TRACK MANUAL LIFT
6’6” 14” Radius 90” 125”
7’0” 14” Radius 96” 125”
8’0” 14” Radius 108” 137”
BACKROOM
JAMB
WEATHER
SEAL
DOOR
STOP
DOOR
SECTION
1/8” TO 1/4”
®
MOTOR
OPERATED
10
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