Wayne-Dalton 9300 User Manual

9300 Series

TorqueMaster® Plus

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 trained door systems
technician do the installation or repairs.

Copyright 2008 Wayne-Dalton Corp. Part No. 327882 Rev 2 3-28-2008

Table of Contents

Important Safety Instructions .................................................. 2

Package Contents ................................................................... 3

Door Section Identification ...................................................... 4

Tools Required ........................................................................ 5

Pre-Installation ....................................................................3-6

Removing An Existing Door ..................................... 5

Preparing The Opening ........................................... 6

Installation ........................................................................7-22

Torquemaster Plus Reset Instructions...............................23-25

Optional Installations .......................................................25-26

Side Lock ............................................................. 25

Pull Rope .............................................................. 26

Trolley Operator .................................................... 26

Maintenance ......................................................................... 26

Cleaning ............................................................... 26

Warranty ............................................................................... 27

Customer Service Number .................................................... 28

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.

WARNING

TO AVOID POSSIBLE INJURY, READ THESE INSTRUCTIONS
CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN
QUESTION ABOUT ANY OF THE PROCEDURES, DO NOT
PERFORM THE WORK. INSTEAD, HAVE A TRAINED DOOR
SYSTEMS TECHNICIAN 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.

17. Avoid installing your door in close proximity to any heat source that
may exceed 200° F. Failure to due so, may cause door sections to
blister and/or warp.

After installation is complete, fasten this manual near garage door.

2

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Package Contents

NOTE: DEPENDING ON THE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT

REQUIRED. REAR SUPPORTS MAY NOT BE INCLUDED WITH YOUR DOOR.

(2) QUICK INSTALL

RH/LH FLAGANGLES (AS

REQUIRED)

(1) CENTER BRACKET

ASSEMBLY

(2) HORIZONTAL ANGLES

(AS REQUIRED)

(2) FULLY ADJUSTABLE

RH/LH FLAGANGLES

(AS REQUIRED)

(2) TOP BRACKET

SLIDES

DOOR SECTIONS (AS REQUIRED)

(1) TORQUEMASTER® SPRING TUBE ASSEMBLY

(2) HORIZONTAL TRACKS RH/LH

WEATHER SEAL & NAILS

(IF INCLUDED)

LH & RH DRUM

ASSEMBLIES WITH

DRUM WRAPS

PRE-INSTALLATION

(2) VERTICAL

TRACKS RH/LH

ARNING

W

in conjunction with the Instructions on the other side of
,

.

D SIDE VIEW

N

t

ENGAGE

Rachet Bracket is under

remove

EXTREME SPRING

TENSIO

T

.

e these Illustration

el

rum

Us

y

able D
C

DO NO

this lab

,

avoid possible severe or

To

fatal injury

Ratchet
n

fasteners from ratchet bracke

e

wnwound.

e

until spring(s) are full

w

bet

t
n

ce

read

No spa

safely unwind spring(s)

Pawl and Cable Drum

G.

tions/owners

To

W

Ratchet Pawl

IE

indicates engageme

TA

V
H

.

T
A
E

RN
NDE
U

manual

VE THIS

and follow the directions in the

ENGAGED

installation instruc

DO NOT REMO

SIDE VIEW

No space between

Ratchet Pawl and

ble Drum

Ca

DISENGAGED

Cable Drum

l
t Paw
e

h
c

Rat

m

nt

able Dru

Space between

and C

tes engageme

W
E
I

V

Ratchet Pawl

TH

A

non-indica

NE

R
E
ND

under

WARNING

DE VIEW

.

SI
ED

N

AG
ENG

Rachet Bracket is

remove

EXTREME SPRING

TENSIO

T

y

DO NO

,
To avoid possible severe or
fatal injury
fasteners from ratchet bracket

wnwound.

until spring(s) are full

read

G.

To safely unwind spring(s)

EW

Ratchet Pawl

I

TA

V
H

.

T
NEA
NDER

manual
and follow the directions in the
installation instructions/owners

DO NOT REMOVE THIS

No space between

END BRACKETS

LH/RH

U

DISENGAGED

POSITION

LOWER

between
space
No

um

Ratchet Pawl and

Cable Dr

TION
I
S
O

UPPER P

n Lower Position

Ratchet Pawl i

W

IDE VIE

Ratchet Pawl in Upper Position

R POSITION S

OWE

L

W

SITION SIDE VIE

UPPER PO

SCREW EYES AND

PULL ROPE

Q.I. JAMB BRACKETS

(AS REQUIRED)

ROLLERS

(AS REQUIRED)

(1) LOOSE WINDING SHAFT

(SINGLE SPRING ONLY)

(IF INCLUDED)

1/4”-20 X 9/16” TRACK

BOLTS (AS REQUIRED)

5/16” X 1-5/8” HEX HEAD LAG

SCREWS (AS REQUIRED)

1/4” - 20

FLANGE HEX NUTS

(AS REQUIRED)

(4) 1/4” -20 X 1”

CARRIAGE BOLTS

STUD PLATES

(AS REQUIRED)

(4) 1/4” -20

NYLOCK HEX NUTS

(2) 3/8” - 16 X 3/4”

TRUSS HEAD BOLTS

(2) 5/16” -18 X 3/4”

CARRIAGE BOLTS

(2) 3/8”- 16

HEX NUTS

(2) 5/16”- 18

HEX NUTS

1/4” - 14 X 5/8”

SELF TAPPING SCREWS

(AS REQUIRED)

1/4”-20 X 11/16” SELF DRILLING

SCREWS (AS REQUIRED)

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

3

Door Section Identification

OPERATOR STILE

All hinges are factory attached at the top of each
section (except the top section). See illustrations
to the right.

NOTE: The side view illustration shows the roller
carrier profile at the top of each section, and
can be used in conjunction with identifying each
section.

The BOTTOM SECTION can be identified by the
bottom astragal and bottom bracket warning
labels.

The LOCK SECTION can be identified by the lock
stile /or side view.

The INTERMEDIATE I SECTION can be identified
by the warning label on either the right or left
hand side of the section /or side view.

The INTERMEDIATE II SECTION can be identified
by the side view (Used ONLY with 5 section
doors).

The TOP SECTION can be identified by no pre­installed end or center hinges, and a factory
attached operator stile.

SIDE VIEW

SIDE VIEW

SIDE VIEW

SIDE VIEW

TOP SECTION

1 7/8”

INTERMEDIATE II SECTION (8”-5 SECTION DOOR ONLY)

2”

WARNING LABEL

INTERMEDIATE I SECTION

1 7/8”

LOCK STILE

LOCK SECTION

BOTTOM BRACKET

WARNING LABELS

ASTRAGAL

BOTTOM SECTION

4

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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Tools Required

POWER DRILL RATCHET WRENCH PLIERS/WIRE CUTTERS

PHILLIPS HEAD SCREWDRIVER PENCIL

7/16”, 1/2”, 9/16”

SOCKETS

FLAT TIP SCREWDRIVER

7/16” SOCKET DRIVER

VICE GRIPSHAMMER SAW HORSES (PAIR)

3/8”, 7/16”, 1/2”, 9/16”

WRENCHES

VICE CLAMPS

Removing An Existing Door

TAPE MEASURE

NEEDLE NOSE PLIERS

SAFETY GLASSES

1/8”, 3/16” DRILL BITS

PRE-INSTALLATION

GLOVES

STEP LADDER

IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING

AN EXISTING DOOR.

WARNING

A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY. TO AVOID INJURY
HAVE A TRAINED DOOR SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS, RELEASE THE SPRING
TENSION.

For detailed information see supplemental instructions “Removing an Existing Door /Preparing the Opening”. These instructions are available
at no charge from Wayne-Dalton Corp., P.O. Box 67, Mt. Hope, OH 44660, or at www.wayne-dalton.com.

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your

local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

5

Preparing the Opening

Header board 2” x
6” lumber preferred

Suitable mounting surface
2” x 6” lumber minimum

Tools Needed:

Recommended

tools from

page 5

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.

To ensure secure mounting of track brackets, side and center brackets, or
steel angles to new or retro-fit construction, it is recommended to follow the
procedures outlined in DASMA Technical Data Sheets #156, #161 and #164 at
www.dasma.com.

The inside perimeter of your garage door opening should be framed with wood
jamb and header material. The jambs and header must be securely fastened to
sound framing members. 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 12” (305 mm) above the top of the opening for TorqueMaster
systems. For low headroom 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.

For TorqueMaster® counterbalance systems, a suitable mounting surface (2”
x 6”) must be firmly attached to the wall, above the header at the center of the
opening.

®

counterbalance

Header

Level header

Plumb jambs

Headroom

Weather Seal

Door height

Door
width

Backroom

Jamb

NOTE: Drill 3/16” pilot holes in the mounting surface to avoid splitting the lumber.
Do not attach the mounting surface with nails.

Weather Seal (May Not Be Included):
Cut the weather seal (if necessary) to fit the header and jambs.

NOTE: If nailing product at 40°F or below, pre-drilling is required.

Align the header seal with the inside edge of the header and temporarily secure
it to the header with equally spaced nails. Next, fit the jamb seals up tight against
the header seal and flush with the inside edge of the jamb. Temporarily secure
the jamb seals with equally spaced nails. This will keep the bottom section from
falling out of the opening during installation. Space nails approximately 12” apart.

NOTE: Do not permanently attach weather seal to the jamb at this time.

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.

Jamb

WEATHER

SEAL

JAMB

QUICK INSTALL

TRACK

TRACK TYPE TorqueMaster

12” 11”

15” 13-1/2”

HEADROOM REQUIREMENT

DOOR

HEIGHT

TRACK

6’5”-7’0” 12”, 15” Radius 98” 125”

8’0” 12”, 15” Radius 110” 137”

MANUAL

LIFT

BACKROOM REQUIREMENT

6

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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

®

MOTOR

OPERATED

Installation

Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb and header must be level. Side clearance,
from edge of door to wall, must be a minimum of 3-1/2” (89mm) on each side.

IMPORTANT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS (NOT SUPPLIED) 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 OR PT 2000 COATED LAG SCREWS ARE NOT NECESSARY WHEN
INSTALLING PRODUCTS ON UNTREATED LUMBER.

IMPORTANT: WHEN INSTALLING 5/16” DIAMETER LAG SCREWS USING AN ELECTRIC DRILL/DRIVER, THE DRILL/DRIVER’S CLUTCH MUST
BE SET TO DELIVER NO MORE THAN 200 IN. LBS. OF TORQUE. FASTENER FAILURE COULD OCCUR AT A HIGHER SETTING.

NOTE: It is recommended that 5/16” lag screws be pilot drilled using a 3/16” drill bit, prior to fastening.

INSTALLATION

1

Tools Needed:

None

Attaching Quick Install Flag

Angle to Vertical Track

NOTE: If you have fully adjustable flagangles, skip

this step and complete Step 2.

Place the lower quick install tab of the flagangle in
the quick install feature of the vertical track. Give
the flagangle 1/4 turn to lock in place. Repeat for
other side.

NOTE: After completing this step, continue with
Step 3.

QUICK INSTALL TAB UNLOCKED

FLAGANGLE

VERTICAL

TRACK

QUICK INSTALL TAB LOCKED

FLAGANGLE

VERTICAL

TRACK

LEFT HAND TRACK AND FLAGANGLE

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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

RIGHT HAND TRACK AND FLAGANGLE

7

2

Attaching Fully Adjustable Flagangle

to Vertical Track

Fully adjustable
flagangle

Tools Needed:

None

NOTE: If quick install flagangles were installed in
Step 1, skip this step and continue with Step 3.

Hand tighten the flagangle to the vertical track
using (1) stud plate and (2) 1/4” - 20 flange hex
nuts. Repeat for other side.

Secure the flange nuts after flagangle spacing is
complete (Step 10).

(2) 1/4”- 20 Flange
hex nuts

Vertical track

Stud plate

3

Tools Needed:

Hammer

Horizontal Angle

Position the horizontal angle as shown.

Place tabs of horizontal angle in the key slot of
horizontal track. Using a hammer, tap the horizontal
angle towards the curved end of the track until the
holes in track and angle are aligned. Repeat for
opposite side. Set tracks aside.

NOTE: For larger doors, a full length horizontal angle
may be spot welded to the horizontal track. If the
horizontal angle is not welded, the horizontal angle
must be installed as shown.

Hole

Horizontal angle

Tabs

Hole

Horizontal track

Horizontal angle

Key hole slot

Horizontal track

Horizontal angle

Horizontal track

Tabs

8

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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

4

Installing Q.I. Jamb Brackets

Tools Needed:

Tape Measure

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 bracket with the quick
install feature in the track and turn the bracket
perpendicular to the track so the mounting flange
is toward the back (flat) leg of the track.

TOP
HOLE

MIDDLE
HOLE

LEFT SIDE SHOWN

TWISTLOCK TAB

RIGHT SIDE SHOWN

3RD SET
HOLES

2ND SET
HOLES

1ST SET
HOLES

INSTALLATION

BOTTOM
HOLE

DOOR

HEIGHT

6’5”

7’0”

8’0”

4 SECTIONS

8’0”

5 SECTIONS

QUICK INSTALL FEATURE

JAMB BRACKET SCHEDULE

TRACK

LENGTH

69”

(1753 mm)

76”

(1930 mm)

88”

( 2235 mm)

88”

(2235 mm)

1ST SET 2ND SET 3RD SET

JAMB BKT POSITION JAMB BKT POSITION JAMB BKT POSITION

QIJB - 3 BOTTOM QIJB - 6 MIDDLE NOT APPLICABLE

QIJB - 3 BOTTOM QIJB - 7 TOP NOT APPLICABLE

QIJB - 3 MIDDLE QIJB - 7 TOP QIJB - 8 MIDDLE

QIJB - 3 BOTTOM QIJB - 7 TOP QIJB - 8 TOP

VERTICAL TRACK

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9