Wayne-Dalton 9600 User Manual

GARAGE DOORS & OPENERS

9100/9400/9600

t o r s i o n

q u i c k s t a r t g u i d e

Table of Contents

Pre - Installation 2

Important Safety Instructions 2 Removing an Existing Door/Preparing the Opening 2

Installation 2 Optional Installations 5 Maintenance 5

Cleaning Your Garage Door 5 Trolley Arm Conﬁguration 5 Painting Your Garage Door 6 Operation and Maintenance 6

Warranty 7 Dealer Locator Information 8

IMPORTANT NOTICE!

The Quick Start Guide is only meant to be used as an aid and/or introduction to garage door installation, and does not replace the complete Installation Instructions and Owner’s manual available on the Wayne-Dalton website.

Wayne-Dalton highly recommends that you read and fully understand the Installation Instructions and Owner’s Manual before you attempt this installation.

To avoid possible injury, read the enclosed instructions carefully before installing and operating the garage door. Pay close attention to all warnings and notes. After installation is complete, fasten this manual near garage door for easy reference.

The Quick Start Guide and Installation Instructions and Owner’s Manual are available at no charge from Wayne-Dalton Corp., P.O. box 67, Mt. hope, OH 44660, or at www.wayne-dalton.com.

PRE - INSTALLATION

Important Safety Instructions

Deﬁnition of key words used in this manual:

WARNING 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.

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 caus-

ing severe or fatal injury.

5. Doors 12’-0” wide and over 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 neces-

sary 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 altera-

tion 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 instruc-

tions.

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. This door may not meet the building code wind load requirements in your area. For your

safety, you will need to check with your local building ofﬁcial for wind load code requirements and building permit information.

After installation is complete, fasten this manual near the garage door. IMPORTANT: STAINLESS STEEL OR PT2000 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 OR PT2000 LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.

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

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

WARNING 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.

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING

LOOKING OUT.

Removing an Existing Door/

Preparing the Opening

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

WARNING 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 not supplied with the door, but are available at no charge from Wayne-Dalton corp., P.O. box 67, Mt. hope, OH 44660, or at www.wayne-dalton.com.

INSTALLATION

Before installing your door, be certain that you have read and followed all of the instructions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door.

Attaching Q.I. Flag Angles to Vertical Tracks

NOTE: If you have F.A. ﬂag angles, skip this step. NOTE: If you have riveted track, skip this step. NOTE: Flag angles are right and left handed.

Place the lower Q.I. tab of the left hand ﬂag angle in the Q.I. feature of the left hand vertical track. Give the ﬂag angle 1/4 turn to lock in place. Repeat for other side.

NOTE: If you have Q.I. ﬂag angles, skip this step. NOTE: If you have riveted track, skip this step. NOTE: Flag angles are right and left handed.

If you have Q.I. vertical tracks, hand tighten the left hand ﬂag angle to the left hand vertical track using (1) stud plate and (2) 1/4” – 20 ﬂange hex nuts. Repeat for the other side.

If you have F.A. vertical tracks, hand tighten the left hand ﬂag angle to the left hand vertical track using (2) 1/4”-20 x 9/16” track bolts and (2) 1/4”-20 ﬂange hex nuts. Repeat for other side. Flange nuts will be secured after ﬂag angle spacing is completed in step, Top Section.

NOTE: For larger doors, a full length horizontal angle may not already be spot welded to the

horizontal track. If the horizontal angle is not welded, the horizontal angle will be installed as shown.

Position the left hand horizontal angle as shown. Place the Q.I. tabs of the horizontal angle in the key slot of the left hand horizontal track. Using a hammer, tap the horizontal angle towards the curved end of the track until the alignment hole in the track and angle are aligned. Repeat for other side. Set tracks aside.

NOTE: If you have F.A. jamb brackets, skip this step. NOTE: If you have riveted track, skip this step.

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 length. To install the jamb brackets, align the Q.I. tab on the Q.I. jamb bracket with the Q.I. feature in the vertical track and turn the bracket perpendicular to the track so the mounting ﬂange is toward the back (ﬂat) leg of the track. Repeat for other side.

Tools: None

Attaching F.A. Flag Angles to Vertical Tracks

Tools: None

Horizontal Angles

Tools: Hammer

Attaching Q.I. Jamb Brackets

Tools: None

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

DOOR HEIGHT

6’0”

6’5”

6’8”

7’0”

7’3”

7’6”

7’9”

8’0” 4-SEC

8’0” 5-SEC

JAMB BRACKET SCHEDULE

TRACK

LENGTH

64” (1626

mm)

69” (1753

mm)

72” (1829

mm)

76” (1930

mm)

79”

(2007mm)

82” (2083

mm)

85” (2159

mm)

88”

(2235mm)

88” (2235

mm)

1ST SET 2ND SET 3RD SET

5 M 6 B NA

3 B 6 M NA

3 B 7 T NA

3 B 5 B 6 B

3 M 6 T 7 M

3 B 7 T 8 T

B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE

IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE SECURING WITH 1/4”-14 X 5/8” SELF TAPPING SCREWS. THERE SHOULD BE NO GAP BETWEEN THE HINGE LEAFS AND THE SECTIONS.

Top Brackets

To install the top brackets, align the top holes in the top bracket base with the second set of holes in the end cap of the top section. Fasten to section 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 ﬂange hex nuts. The bracket will be tightened and adjusted later, in step, Adjusting Top Brackets. Insert roller into top bracket slide. Repeat for other side.

Tools: Power drill, 7/16” Socket driver

U-bar

NOTE: If a u-bar is supplied, complete this step.

Place the 3” u-bar over the top rib of the top door section. Fasten each end of the u-bar to the end cap with (2) 1/4”- 20 x 11/16” self drilling screws. Fasten center of the u-bar as shown to the rib using (2) 1/4”-14 x 5/8” self tapping screws, one 6” to the left and one 6” to the right of the center line of the top door section.

Tools: Power drill, 7/16” Socket driver, Tape measure

U-bar Asymmetrical

Tools: Power drill, 7/16” Socket driver, Tape measure

Attaching F.A. Jamb Brackets

NOTE: If you have Q.I. jamb brackets, skip this step. NOTE: If you have riveted track, skip this step. NOTE: The bottom jamb bracket is always the shortest bracket, while the center jamb bracket

is the next tallest. If three jamb brackets per side are included with your door, you will have received a top jamb bracket, which is the tallest.

To attach the bottom jamb bracket, locate lower hole of the hole/ slot pattern of the 1st hole set on the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/ slot pattern. Secure jamb bracket using (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”-20 ﬂange hex nut. Repeat for other side.

Place the center jamb bracket over the lower hole of the hole/ slot pattern that is centered between the bottom jamb bracket and ﬂag angle of the 2nd hole set. Secure jamb bracket using (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”-20 ﬂange hex nut. Repeat for other side.

If a top jamb bracket was included, secure it to vertical track using the lower hole of the hole/ slot pattern in the 3rd hole set and (1) 1/4”-20 x 9/16” track bolt and (1) 1/4”-20 ﬂange hex nut. Repeat for other side.

Tools: None

Bottom Section

Center the bottom section in the door opening. Level the section using wooden shims (if necessary) under the bottom section.

Tools: Level, Wooden shims (if necessary)

Vertical Tracks

IMPORTANT: THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE. IF

THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.

Position the left hand vertical track assembly over the rollers of the bottom section. Make sure the counterbalance cable is located between the rollers and the door jamb. Drill 3/16” pilot holes into the door jamb for the lag screws.

Loosely fasten jamb brackets and ﬂag angle to the jamb using 5/16” x 1-5/8” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing as shown between the bottom section and vertical track. Hang cable drum over ﬂag angle. Repeat for other side.

Tools: Power Drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure, Level, Step ladder

Stacking Sections

NOTE: Make sure hinges are ﬂipped down, when stacking another section on top.

Place rollers into end hinges of remaining sections. With assistance, lift second section and guide rollers into the vertical tracks. Lower section until

it is seated against bottom section. Flip hinges up. Fasten intermediate hinge(s) ﬁrst; then end hinges using 1/4”-14 x 5/8” self tapping screws. Repeat for other sections, except top section.

Tools: Power drill,7/16” Socket driver

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

NOTE: If an asymmetrical u-bar is supplied, complete this step. Place the 3” asymmetrical u-bar over the top rib of the top door section. Fasten each end of the

u-bar to the end cap with (2) 1/4”- 20 x 11/16” self drilling screws. Fasten center of the u-bar as shown to the rib using (2) 1/4”-14 x 5/8” self tapping screws, one 6” to the left and one 6” to the right of the center line of the top door section.

Fasten both walls of the u-bar as shown using (2) 1/4”-14 x 5/8” self tapping screws every 3036 inches. (Approximately 18 self tapping screws per 18’ u-bar)

Operator Bracket

NOTE: If you’re installing a trolley operator, the operator bracket must be mounted and secured

prior to installing top section. IMPORTANT: WHEN CONNECTING A TROLLEY TYPE GARAGE DOOR OPENER TO THIS DOOR, A

WAYNE-DALTON OPERATOR/ TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY U-BARS PROVIDED WITH THE DOOR. THE INSTALLATION OF THE OPERATOR MUST BE ACCORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY.

Prior to installing top section, locate the center of the top section and seat the operator bracket on top of the top section. For retro ﬁt applications, the operator bracket must be aligned with an existing operator and positioned on top section so it bridges the transition point of the section thickness. Install (2) #12 x 1/2” phillips head screws on the back side of operator bracket. Clamp operator bracket to u-bar (if supplied) with vice clamps. Attach (5) 1/4” - 14 x 5/8” selftapping screws to the operator bracket. Remove vice clamps.

NOTE: If a u-bar was installed, you can use two of the 1/4” - 20 x 11/16” self-drilling screws previously used to attach the u-bar instead of two 1/4”-14 x 5/8” self-tapping screws when attaching operator bracket to u-bar.

NOTE: When attaching operator bracket to top section with u-bar, apply additional pressure to thread into the u-bar.

Tools: Power drill, 7/16” Socket driver, Phillips head screwdriver, Vice clamps, Tape measure

Top Section

Place the top section in the opening. 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 the hinge leaves, hold tight against section, and fasten center hinges ﬁrst and end hinges last (refer to step, Stacking Sections). Vertical track alignment is critical. Position ﬂag angle between 1-11/16” (43 mm) to 1-3/4” (44 mm) from the edge of the door; tighten the bottom lag screw. Flag angles must be parallel to the door sections. Repeat for other side.

IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES MUST BE DOOR WIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERATION.

For Q.I. track:

Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Repeat for other side.

For F.A. track:

Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Push the vertical track against the rollers so that the rollers are touching the deepest part of the curved side of the track as shown; tighten all the track bolts and nuts. Repeat for other side.

Tools: Hammer, Step ladder, Tape measure

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