Page 1
9100, 9400 and 9600 Series
TorqueMaster® Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
Portland Source Plant
IMPORTANT NOTICE!
Read these instructions carefully before
attempting installation. If in question about
Wayne-Dalton Corp.
P.O. Box 67
Mt. Hope, OH 44660
www.wayne-dalton.com
Copyright 2009 Wayne-Dalton Corp. Part No. 328740 REV1 08/03/2009
any of the procedures, do not perform the
work. Instead, have a trained door systems
technician do the installation or repairs.
Page 2
Table of Contents
Important Safety Instructions ............................................ 2
Package Contents ............................................................. 3
Door Section Identification ................................................ 4
Tools Required .................................................................. 5
Removing an Existing Door ...............................................5
Installation ..................................................................7-28
TorqueMaster
Side Lock .......................................................32
Pull Rope ........................................................ 32
Step Plate ....................................................... 33
Trolley Installation for Standard Lift................. 34
Trolley Installation for Low Headroom ............. 35
Trolley Operator .............................................. 36
Maintenance ................................................................... 37
Cleaning ......................................................... 37
Painting Instructions ..................................37-38
Warranty ......................................................................... 39
Dealer Locator Information.............................................. 40
®
Plus Reset Instructions..........................29-31
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.
After installation is complete, fasten this manual
near garage door.
2
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Page 3
Package Contents
Cable Drum
No space betw
een Ratchet
Pawl
and Cabl
e Drum
indicates
engagem
ent
Cable Drum
Ratchet
Pawl
ENGAGED SI
DE VIEW
No space betw
een
Ratchet
Pawl
and
Cable Drum
ENGA
GED UNDERNEATH VIEW
Space between Ratchet Pawl
and Cabl
e Drum
non-indicates engagem
ent
Cable Drum
Ratchet Pawl
DISENGAGED
SIDE VIEW
No space betw
ee
n
Ratchet
Pawl
and
DISENGA
GED U
NDERNEATH VIEW
UPPER
POSITION
LOWER POSI
TION
LOWER
POSITION
SIDE VIEW
UPPER
POSITION SIDE VIEW
Ratchet Pawl
in Low
er Position
Ratchet
Pawl in Upper Pos
ition
Use these Illustration
, in conjunction with
the Instructions on the other side of
this label.
WARNING
Rachet Bracket is under
EXTREME SPRING
TENSION
.
To avoid possible severe or
fatal injury,
DO NOT
remove
fasteners from ratchet bracket
until spring(s) are fully
wnwound.
To safely unwind spring(s)
read
and follow the directions
in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Ratchet
Pawl
ENGAGED
SIDE VIEW
No space betw
een
NDERNE
ATH VIEW
WARNING
Rachet Bracket is under
EXTREME SPRING
TENSION
.
To avoid possible severe or
fatal injury,
DO NOT
remove
fasteners from ratchet bracket
until spring(s) are fully
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
(2) HORIZONTAL TRACKS RH/LH
DOOR SECTIONS (AS REQUIRED)
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.
(2) FULLY ADJUSTABLE
RH/LH FLAGANGLES
(2) DRUM WRAPS
LH/RH
(2) TOP BRACKET
BASES
(1) OPERATOR BRACKET
(1) TORQUEMASTER
(1) CENTER BRACKET
ASSEMBLY
(2) TOP BRACKET
SLIDES
WEATHER SEAL &
NAILS (IF INCLUDED)
®
SPRING TUBE
(1) LOOSE WINDING SHAFT
(SINGLE SPRING ONLY)
ROLLERS
(AS REQUIRED)
ASYMMETRICAL U-BAR
(IF INCLUDED)
RIGHT AND LEFT CABLE
DRUM ASSEMBLIES
#6 SCREW EYE AND PULL
ROPE (IF INCLUDED)
U-BAR
(IF INCLUDED)
END BRACKETS
LH/RH
(2) VERTICAL
RH/LH TRACKS
QUICK INSTALL JAMB
BRACKETS (AS REQUIRED)
5/16” X 2” HEX LAGS (AS REQUIRED)
5/16”- 18 HEX NUTS
(AS REQUIRED)
5/16” - 18 X 3/4” CARRIAGE
BOLTS (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
1/4”- 20 FLANGE HEX
NUTS (AS REQUIRED)
3/8”- 16 HEX
NUTS (AS REQUIRED)
1/4”- 20 X 5/8” CARRIAGE
BOLTS (AS REQUIRED)
1/4”- 20 X 11/16” SELF DRILLING
SCREWS (AS REQUIRED)
(1) COTTER PIN
(2) #12 X 1/2”
1/4”- 14 X 5/8” SELF TAPPING
SCREWS (AS REQUIRED)
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
PHILLIPS HEAD
SCREWS
3/8”- 16 X 3/4”
HEX HEAD
BOLTS (AS REQUIRED)
(1) 5/16” X 1-1/4”
CLEVIS PIN
3
Page 4
Door Section Identification
Tools Needed:
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 a #1 end hinge, the factory attached
astragal, or by the bottom bracket warning
labels on each end stile. This section is
always the 1st section from the bottom of
the door.
The LOCK SECTION can be identified by a
#2 end hinge. This section is always the
2nd section from the bottom of the door.
The INTERMEDIATE SECTION can be
identified by a #3 end hinge. Sections will
have a warning label attached to either the
left or the right end stile of the section.
This section is always the 3rd section from
the bottom of the door.
WARNING LABEL
#4
#3
#2
#1
ASTRAGAL
TOP SECTION
INTERMEDIATE II SECTION
WARNING LABEL
INTERMEDIATE SECTION
LOCK SECTION
BOTTOM BRACKET
WARNING LABELS
BOTTOM SECTION
SECTION SIDE VIEW
The INTERMEDIATE II SECTION can be
identified by a #4 end hinge. This section if
always the 4th section from the bottom of
7/8”
1 1/8”
1 3/8”
1 19/32”
the door on five section doors only.
The TOP SECTION can be identified with
no pre-installed end or center hinges on
the section and the warning label attached
in the upper middle of the section.
TYPICAL HINGE STAMPING LOCATION
#1 END
HINGE
BOT.
BOTTOM
BRACKET
ASTRAGAL
#2 END
HINGE
LOCK
#3 END
HINGE
INT.
#4 END
HINGE
INT II
(USED ONLY
ON FIVE
SECTIONS)
4
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
TOP
Page 5
Tools Required
PENCIL
3” EXTENSION
SAWHORSE
RATCHET WRENCH
FLAT TIP SCREWDRIVER
PLIERS/CUTTERS
VICE GRIPS
HACKSAW
Removing An Existing Door
1/2”, 7/16” SOCKET
DRIVER
3/16”, 7/16” & 1/8”
DRILL BITS
TAPE MEASURE
PHILLIPS HEAD
SCREWDRIVER
GLOVES
SAFETY GLASSES
5/8”, 1/2”, 7/16”
& 9/16” SOCKET
1/2, 7/16” & 9/16”
VICE CLAMPS
POWER DRILL
LEVEL
HAMMER
WRENCHES
STEP LADDER
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
Page 6
P1
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.
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
mounting surface (2” x 4”) must be firmly attached to the wall,
above the header at the center of the opening.
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 (May Not Be Included):
Cut or trim the weather seal (if necessary) to the header and jambs.
For quick install track: 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.
NOTE: 6” LHR Conversion Kit is available for 12” Radius only.
Contact your local Wayne-Dalton dealer.
BACKROOM REQUIREMENT: Backroom is defined as the distance
needed from the opening back into the garage to allow the door to
open fully.
Plus counterbalance systems, a suitable
HEADROOM
REQUIREMENT
TRACK
10”, 12” 10”
LHR Kit 6 1/2”
TORQUEMASTER
TYPE
14” 12”
PLUS
®
Plus counterbalance
®
SUITABLE MOUNTING
SURFACE 2” X 6”
HEADER BOARD
2” X 6” LUMBER
PREFERRED
LEVEL HEADER
PLUMB JAMBS
DOOR
WIDTH
HEADROOM
HEADER
WEATHER SEAL
JAMB
JAMB
LUMBER MINIMUM
DOOR HEIGHT
BACKROOM
WEATHER
SEAL
BACKROOM REQUIREMENT
DOOR
HEIGHT
6’5” 10”, 12”, 14” Radius 89” 125”
6’5” Low Headroom 101” 125”
6’6” 10”, 12”, 14” Radius 90” 125”
6’6” Low Headroom 102” 125”
7’0” 10”, 12”, 14” Radius 96” 125”
7’0” Low Headroom 108” 125”
7’6” 10”, 12”, 14” Radius 102” 137”
7’6” Low Headroom 114” 137”
8’0” 10”, 12”, 14” Radius 108” 137”
8’0” Low Headroom 120” 137”
TRACK
MANUAL
LIFT
JAMB
MOTOR
OPERATED
6
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Page 7
Installation
12”
12”
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 the
header level. Side clearance, from edge of door to wall, must be minimum of 3-1/2” (89 mm) on each side.
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 UNTREATED
LUMBER.
NOTE: It is recommended that 5/16” x 2” lag screws will be pilot drilled using a 3/16” drill bit, prior to fastening.
NOTE: If you have riveted track, skip steps, 1 through 2 and proceed to step3.
Cutting Vertical Track and
1
1
Tools Needed:
Tape Measure
Hacksaw
Power Drill
5/16” Drill Bit
Installing Q.I. Jamb Brackets
Vertical track must be cut to the proper
length prior to installation.
IMPORTANT: DOORS THAT ARE 7’-0” OR
8’-0” IN HEIGHT DO NOT REQUIRE CUTTING
THE VERTICAL TRACK.
Determine the radius of your horizontal
track.
NOTE: All Portland tracks have the radius
stamped on the side of the track.
Using this measurement, refer to the vertical
track cutting chart to determine the length
of the vertical track. Cut the track off at the
TOP.
Now, two holes must be drilled into the
top of the cut vertical track. Refer to the
illustration shown for hole locations. Use a
5/16” drill bit.
Repeat for other vertical track.
Measure the length of the vertical tracks.
Using the jamb bracket schedule, determine
the placement of the jamb brackets for your
door height.
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.
3RD SET HOLES
LEFT SIDE SHOWN
2ND SET HOLES
RIGHT SIDE SHOWN
TWISTLOCK TAB
INSTALLATION
Horizontal
track
Stamped
radius
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
QI JAMB BRACKET
TOP
HOLE
MIDDLE
HOLE
BOTTOM
HOLE
QUICK INSTALL FEATURE
1ST SET HOLES
7
Page 8
Cutting Vertical Track and
Installing Q.I. Jamb Brackets
Tools Needed:
Tape Measure
Hacksaw
Power Drill
5/16” Drill Bit
Vertical Track Cutting Chart
Horizontal
Track Radius
10”, 12” Door Height Minus 10”
14” Door Height Minus 8”
3-1/2” LHR Door Height Minus 15”
6-1/2” LHR Door Height Minus 12”
5/8”
Vertical Track Cut Length
1/2”
5/8”
5/16”
Continued
Vertical Track Cut Length
Cut vertical
track here
JAMB BRACKET SCHEDULE
DOOR
HEIGHT
6’0” QIJB-3 MIDDLE QIJB-6 TOP NOT APPLICABLE
6’5” QIJB-3 MIDDLE QIJB-5 BOTTOM NOT APPLICABLE
6’8” QIJB-3 MIDDLE QIJB-5 BOTTOM NOT APPLICABLE
7’0” QIJB-3 MIDDLE QIJB-5 BOTTOM NOT APPLICABLE
7’3” QIJB-3 MIDDLE QIJB-5 MIDDLE QIJB-6 MIDDLE
7’6” QIJB-3 MIDDLE QIJB-5 MIDDLE QIJB-6 MIDDLE
7’9” QIJB-3 MIDDLE QIJB-5 MIDDLE QIJB-6 MIDDLE
8’0”
(4 SECTION)
8’0”
(5 SECTION)
1ST SET 2ND SET 3RD SET
JAMB
QIJB-3 MIDDLE QIJB-5 MIDDLE QIJB-6 MIDDLE
QIJB-3 BOTTOM QIJB-5 BOTTOM QIJB-6 BOTTOM
BKT
POSITION
JAMB
BKT
POSITION
JAMB
BKT
POSITION
Horizontal
2
track
Tools Needed:
None
Attaching Fully Adjustable
Flagangle to Vertical Track
Hand tighten the flagangle to the
vertical track using (2) 1/4”- 20 x 5/8”
carriage bolts and (2) 1/4”- 20 flange
hex nuts.
Repeat for opposite side.
The flange nuts will be tightened after
flagangle spacing is complete (Step 11).
FULLY
ADJUSTABLE
FLAGANGLE
(2) 1/4”- 20
FLANGE HEX NUTS
(2) 1/4”- 20 X 5/8”
CARRIAGE BOLTS
VERTICAL
TRACK
8
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Page 9
3
Counterbalance Drums
LEFT HAND TORQUEMASTER®
PLUS COUNTER BALANCE DRUM
BOTTOM SECTION
#1 END HINGE
(HINGE TUBE)
Tools Needed:
None
IMPORTANT: RIGHT AND LEFT HAND
IS ALWAYS DETERMINED FROM INSIDE
THE BUILDING LOOKING OUT.
NOTE: For door section identification
see page 4.
TorqueMaster® Plus counterbalance
drums are marked right and left hand.
Uncoil the counterbalance cables and
make sure you place the right hand
cable loop on the right hand milford
pin and place the left hand cable loop
on the left hand milford pin. Insert a
roller into bottom bracket of the bottom
section and insert another roller at
#1 end hinge at the top of the bottom
section. Repeat for other side.
COUNTERBALANCE
ASTRAGAL
CABLE
MILFORD PIN
ROLLERS
BOTTOM BRACKET
BOTTOM
SECTION
INSTALLATION
4
Tools Needed:
Level
Bottom Section
Center the bottom section in the door
opening. Level section using wooden
shims under the bottom astragal if
necessary.
WEATHER SEAL
DOOR OPENING
LEVEL
BOTTOM
SECTION
WOODEN SHIMS
(IF NECESSARY)
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
9
Page 10
5
Vertical Track
FLAGANGLE
Tools Needed:
3/16” Drill Bit
Power Drill
7/16” Socket
Driver
Tape Measure
Level
Step Ladder
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.
NOTE: Vertical track needs held 1/2” off
ground.
Drill 3/16” pilot holes for the lag
screws. Loosely fasten jamb brackets
and flagangle to the jamb using
5/16” x 2” lag screws.
On the bottom jamb bracket, tighten
the lag screw securing the bottom jamb
bracket to the jamb, to maintain the
5/8” spacing.
5/16” X 2” LAG
SCREWS
CABLE
VERTICAL
TRACK
ASSEMBLY
BOTTOM SECTION
JAMB
BRACKET
Hang the cable drum over the flagangle.
Repeat for the right hand side.
QUICK INSTALL
JAMB BRACKET
LAG
SCREW
LOCATIONS
LAG
SCREW
VERTICAL TRACK
BOTTOM
SECTION
ROLLER
10
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5/8”
Page 11
6
Stacking Sections
Tools Needed:
Power Drill
7/16” Socket
Driver
NOTE: For door section identification
see page 4.
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 the second section
and guide rollers into the vertical
tracks.
Maintaining section vertical alignment;
starting with the center hinge first,
flip up the hinge leaf, and hold it tight
against the section. Secure it to the
section with (3) 1/4”-14 x 5/8” self
tapping screws.
Attach center hinges first, then attach
the end hinges last.
Now, secure the end hinge leafs to the
section with (2) 1/4” -14 x 5/8” self
tapping screws and fasten them in a
low to high inclination (from bottom
left hole, to upper right hole, for the left
side of the door and from bottom right
hole, to upper left hole, for the right
side of the door).
LOCK SECTION
INSTALLATION
Repeat for other section(s) except top
section.
IMPORTANT: PUSH & HOLD THE
HINGE LEAF AGAINST SECTION WHILE
SECURING WITH 1/4”-14 X 5/8” SELF
TAPPING SCREWS. END HINGES HAVE
(2) SCREWS AND INTERMEDIATE
HINGES HAVE (3) SCREWS.
END HINGES (LEFT HAND SHOWN, RIGHT HINGE SYMMETRICALLY OPPOSITE)
NOTE: Install lock at this time (sold
separately). See instructions in
OPTIONAL SIDE LOCK INSTALLATION
on page 32.
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
DO NOT USE
(2) 1/4”-14 X 5/8”
SELF TAPPING SCREWS
(3) 1/4”-14 X 5/8” SELF
TAPPING SCREWS
INTERMEDIATE HINGES
11
Page 12
7
Tools Needed:
Power Drill
7/16” Socket
Driver
Top Brackets
NOTE: The top brackets may be pre-
assembled in some cases.
To install the L-shaped top brackets,
align the top holes in the top bracket
base with:
a) the second set of holes in the endstile
for 14” radius track.
TOP SECTION
1ST SET
(10” & 12” RADIUS)
2ND SET
(14” RADIUS)
TOP BRACKET BASE
(4) 1/4” - 14 x 5/8”
SELF TAPPING
SCREWS
b) the first set of holes in the endstile for
10” & 12” radius track.
Fasten using (4) 1/4”- 14 x 5/8” self
tapping screws.
Hand tighten the top bracket slide to the
bracket base using (2) 1/4”- 20 x 5/8”
carriage bolts and (2) 1/4”-20 flange
hex nuts.
The top bracket slide will be tightened
and adjusted in Step 13. Insert rollers
into top bracket slide. Repeat for other
side.
(2) 1/4”- 20 x 5/8”
CARRIAGE BOLTS
TOP BRACKET SLIDE
TOP SECTION
(2) 1/4”- 20
FLANGE HEX
NUTS
ROLLER
TOP SECTION
12
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TOP BRACKET SLIDE
Page 13
8
Tools Needed:
Power Drill
7/16” Socket
Driver
U-Bar
NOTE: If you have a model 9400/9600
Series door with windows in the top
section or 9100 Sonoma (8’ high), skip
this step and complete step 9.
NOTE: Model 9100 Series door over 13’
wide require a 3” U-Bar (supplied).
Place the 3” U-bar over the top rib.
Fasten each end of the U-bar to the
endstile 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 6” to the left and 6”
inches to the right of the center of the
door section.
NOTE: Upon completion of this step,
continue with Step 10.
(4) 1/4”- 20 X 11/16”
SELF DRILLING SCREWS
U-BAR
1/4”-14 X 5/8” SELF
TAPPING SCREWS
TOP DOOR SECTION
6”
(INSTALLED IN
6”
OPERATOR
BRACKET
STEP 10)
INSTALLATION
ATTACHING CENTER OF U-BAR ATTACHING ENDS OF U-BAR
9
Tools Needed:
Power Drill
7/16” Socket
Driver
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U-Bar - Asymmetrical
NOTE: If a 3” U-Bar was installed in Step 8,
skip this step and continue with Step 10.
NOTE: Model 9400/9600 glazed top doors
13’-0” wide or greater will be supplied
with a 3” asymmetrical U-bar for the top
section.
Place the 3” asymmetrical U-bar over the
top rib. Fasten each end of the U-bar to
the endstile 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 6” off of the center of the door
section.
Fasten both walls of the U-bar as shown
using 1/4”- 14 x 5/8” self tapping screws
every 30-36 inches for the top of the U-bar
and every 16-18 inches for the bottom of
the U-bar. (approximately 18 self tapping
screws per 18’ U-bar)
30” TO 36”
16” TO 18”
(2) 1/4”- 20 X 11/16”
SELF DRILLING SCREWS
ATTACHING CENTER OF U-BAR
1/4”- 14 X 5/8” SELF
TAPPING SCREWS
U-BAR
16” TO 18”
TOP DOOR SECTION
ATTACHING INTERMEDIATES OF U-BAR
6”
OPERATOR
BRACKET
(INSTALLED IN
STEP 10)
6”
13
Page 14
10
Tools Needed:
Power Drill
7/16” Socket
Driver
Vice Clamps
Phillips Head
Screwdriver
Operator Bracket
NOTE: 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
OPENER/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 OPENER MUST BE ACCORDING TO
MANUFACTURER’S INSTRUCTIONS AND
FORCE SETTINGS MUST BE ADJUSTED
PROPERLY.
Locate the center of the top section and
place the operator bracket on top of the
section as illustrated. Align the center
of the bracket with the center line of the
top section. For retro fit applications, the
operator bracket must be aligned with an
existing operator and positioned on the top
section as illustrated.
Install (2) #12 x 1/2” phillips head screws
on the top flange of the operator bracket.
U-BAR INSTALLED: If a U-Bar is installed
on the top section, clamp the bottom
flange of the operator bracket to the U-Bar.
Make sure the bottom flange of the bracket
is held in place, flush against the U-Bar
before continuing.
CENTER
LINE
TOP SECTION
WITH OR
WITHOUT U-BAR
TOP
FLANGE
TOP FLANGE INSTALLATION
FRONT
OPERATOR
BRACKET
(2) #12 X 1/2”
PHILLIPS HEAD
SCREWS
OPERATOR
BRACKET
TOP
FLANGE
U-BAR
NOTE: NOT REQUIRED FOR J-STRUTS.
FRONT
BOTTOM
FLANGE
TOP
SECTION
OPERATOR BRACKET
BOTTOM
FLANGE
VICE CLAMP
INSTALLATION WITH U-BAR
(2) 1/4”- 14 X 5/8”
SELF TAPPING SCREWS
U-BAR
NO U-BAR INSTALLED: If a U-Bar is not
installed on the top section, continue with
the steps below.
Secure the front of the operator bracket to
the section using (3) 1/4”-14 x 5/8” self
tapping screws. Next, using
U-BAR
(2) 1/4”-14 x 5/8” self tapping screws,
secure the bottom flange of the operator
bracket to the U-Bar (if installed) or section
rib. Remove vice clamps if placed on
operator bracket previously.
NOTE: If you have a 9100 door, use (2)
1/4”- 20 x 11/16” self drilling screws to
secure the operator bracket instead of the
(4) 1/4”- 14 X 5/8”
SELF TAPPING
SCREWS
INSTALLATION WITH U-BAR
(2) 1/4”- 20 X
11/16” SELF
TAPPING SCREWS
INSTALLATION WITH U-BAR
(5) 1/4”- 14 X 5/8”
SELF TAPPING
SCREWS
U-BAR
(2) 1/4”- 14 x 5/8” self tapping screws
when securing the operator bracket to
U-Bar.
OPERATOR
BRACKET
NOTE: When attaching an operator bracket
to the top section with a U-Bar installed,
apply additional pressure to thread the
fasteners into the U-Bar.
BOTTOM
FLANGE
INSTALLATION WITHOUT U-BAR
FRONT OF
OPERATOR
BRACKET
14
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OPERATOR
BRACKET
BOTTOM
FLANGE
Page 15
11
Top Section
Tools Needed:
Hammer
Tape Measure
Power Drill
7/16” Socket
Driver
7/16” Wrench
Place the top section in the opening
and vertically align with lower sections.
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 leaf against section,
fastening center hinges first, and end
hinges last. (Refer to Step 6).
When installing a door with
Torquemaster® Plus counterbalance
system, vertical track alignment is
critical.
Position flagangle between 1-11/16”
(43 mm) to 1-3/4” (44 mm) from the
edge of the door. Tighten the bottom
lag screw. Flagangles must be parallel
to the door sections.
Repeat for opposite side.
DOOR WIDTH
+3-3/8” TO 3-1/2”
INSTALLATION
IMPORTANT: THE DIMENSION
BETWEEN THE FLAGANGLES MUST BE
DOOR WIDTH PLUS 3-3/8” (86MM) TO
3-1/2” (89 MM) FOR SMOOTH, SAFE
DOOR OPERATION.
Now complete the vertical track
installation by securing the center jamb
bracket(s), flagangle, and connection of
the vertical track/flagangle.
Repeat for opposite side.
NAIL
TOP SECTION
1-11/16” TO 1-3/4”
FLAGANGLE
TOP
SECTION
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15
Page 16
12
Attaching Horizontal Track to
Fully Adjustable Flagangle
Tools Needed:
9/16” Socket
7/16” Socket
Ratchet Wrench
9/16” Wrench
Level
Hammer
Step Ladder
To install horizontal track, place the
curved end over the top roller. Align
the bottom of the horizontal track with
the vertical track. Hand tighten the
horizontal track to the flagangle with (2)
1/4”- 20 x 5/8” carriage bolts and (2)
1/4”- 20 flange hex nuts.
WARNING
DO NOT RAISE DOOR UNTIL
HORIZONTAL TRACKS ARE
SE CURED AT REAR, AS OUTLINED
IN STEP 24, OR DOOR COULD
FALL FROM OVERHEAD
POSI TION CAUSING SEVERE OR
FATAL INJURY.
Level the horizontal track assembly and
bolt the horizontal angle to the slot in
the flagangle using (1) 3/8”- 16 x 3/4”
hex head bolt and (1) 3/8”- 16 hex nut.
Repeat for other side.
NOTE: If an idrive® opener will be
installed, position horizontal tracks
slightly above level.
FLAGANGLE
(2) 1/4”- 20 FLANGE
HEX NUTS
HORIZONTAL
TRACK
(2) 1/4”- 20 X 5/8”
CARRIAGE BOLTS
VERTICAL TRACK
Tighten the remaining carriage bolts
and nuts to complete the horizontal
track installation.
Remove the nail that was temporarily
holding the top section in place,
installed in Step 11.
IMPORTANT: FAILURE TO REMOVE NAIL
BEFORE ATTEMPTING TO RAISE DOOR
COULD CAUSE PERMANENT DAMAGE
TO TOP SECTION.
HORIZONTAL ANGLE
(1) 3/8”- 16
HEX NUT
(1) 3/8”- 16 X 3/4”
HEX HEAD BOLT
HORIZONTAL
TRACK
16
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Page 17
13
Tools Needed:
7/16” Wrench
Step Ladder
Adjusting Top Brackets
With horizontal tracks installed, you can
now adjust the top brackets. Vertically
align the top section of the door with the
lower sections. Once aligned, position
the top bracket slide, out against the
horizontal track.
Maintaining the slide’s position, tighten
the (2) 1/4”- 20 flange hex nuts to
secure the top bracket slide to the top
bracket base.
HORIZONTAL
TRACK
TOP
ROLLER
TOP
BRACKET
SLIDE
TOP
SECTION
TOP
SECTION
(2) 1/4”- 20
FLANGE HEX
NUTS
TOP
SECTION
INSTALLATION
CORRECT
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INCORRECT
17
Page 18
14
TorqueMaster® Spring Tube
Tools Needed:
None
TorqueMaster® springs come lubricated
and pre-assembled inside the
TorqueMaster® spring tube. To install,
lay the TorqueMaster® spring tube on
the floor (inside garage) in front of the
door with the labeled end to the left.
TORQUEMASTER®
SPRING TUBE
LABELED END
15
Tools Needed:
None
Center Bracket Bushing
NOTE: If you are installing the
with your garage door, skip this step
and go to your idrive® Installation
Instructions and Owner’s Manual.
After completing steps 1-13 of your
idrive® Insatallation Instructions and
Owner’s Manual, rear supports will to
be fabricated/installed to support the
horizontal tracks see step 24.
NOTE: If you are not installing the
idrive® opener on your garage door, you
must install the center bracket bushing
assembly. Follow these instructions for
non-idrive® operated garage doors.
Being cam shaped the center bracket
bushing only fits one way.
Slide the center bracket assembly
towards the center of the
TorqueMaster® spring tube, from the
right side as shown.
®
opener
TORQUEMASTER
SPRING TUBE
CENTER
BRACKET
ASSEMBLY
®
TORQUEMASTER®
SPRING TUBE
CENTER
BRACKET
BUSHING
18
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Page 19
16
Drum Wraps
Tools Needed:
None
IMPORTANT: RIGHT AND LEFT HAND
IS ALWAYS DETERMINED FROM INSIDE
THE GARAGE LOOKING OUT.
Drum wraps are identified as right and
left.
Slide the left hand drum wrap over the
left side of the TorqueMaster® spring
tube assembly with the tabs facing
left. Continue sliding the left hand
drum wrap towards the center of the
TorqueMaster® spring tube assembly.
Repeat for opposite side.
RIGHT HAND DRUM WRAP
LEFT HAND DRUM WRAP
INSTALLATION
TORQUEMASTER®
SPRING TUBE ASSEMBLY
LEFT HAND
DRUM WRAP
TABS
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19
Page 20
17
Use
the
se Illustration,
this l
abel.
Cable Drums
TORQUEMASTER®
SPRING TUBE ASSEMBLY
Tools Needed:
Tape Measure
Step Ladder
Shake the TorqueMaster® spring tube
assembly gently to extend the winding
shafts out about 5" on each side. For
single spring applications, there will be
no left hand spring in the
TorqueMaster® spring tube assembly.
Lift the TorqueMaster® spring tube
assembly and rest it on the top of the
flagangles.
NOTE: Cable drums are marked right
and left hand. Cable drums and
TorqueMaster® spring tube assembly
are cam shaped to fit together only one
way.
Pre-wrap the TorqueMaster® Plus
cable drum with the counter balance
cable either 1/2 or 1-1/2 wraps (see
illustrations).
To install the cable drum, slide the
correct cable drum over the winding
shaft until the cable drum seats against
the TorqueMaster® spring tube
assembly.
The winding shaft must extend past the
cable drum far enough to expose the
splines and the groove. Align the
winding shaft groove with the round
notch in the flagangle.
For double spring applications:
Repeat for opposite side.
WINDING
SHAFT
5”
TorqueMaster® Spring Tube
Assembly
TorqueMaster® Spring Tube
Assembly
Right Drum
1/2 Wrap Shown
Right Drum
1-1/2 Wrap Shown
GROOVE
ROUND NOTCH
FLAGANGLE
Counterbalance Cable
Counterbalance Cable
SPLINES
WINDING SHAFT
CABLE
DRUM
For single spring applications: Insert
the loose winding shaft into the left
hand cable drum prior to sliding the
cable drum over the TorqueMaster®
spring tube assembly.
COUNTERBALANCE CABLE
NOTE: On single spring applications,
take care in handling the loose winding
WINDING SHAFT
shaft (left side) so that it does not slide
back into the TorqueMaster® spring
tube assembly.
CABLE
DRUM
GROOVE
SPLINES
LOOSE WINDING SHAFT
20
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Page 21
Cable Drum
No space between Ratchet
Pawl and Cable Drum
indicates engagement
Cable Drum
Ratchet Pawl
ENGAGED SIDE VIEW
No space between
Ratchet Pawl and
Cable Drum
ENGAGED UNDERNEATH VIEW
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED U
NDERNEATH VIEW
UPPER POSITION
LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in conjunction with the Instructions on the other side of
this label.
WA RNING
Rachet Bracket is under
EXTREME SPRING
TENSION
.
To avoid possible severe or
fatal injury,
DO NOT
remove
fasteners from ratchet bracket
until spring(s) are fully
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Cable Drum
No s
pace between
Ratche
t
Pawl and Cable Drum
indicates engagement
Cab
le D
rum
Ratchet
Pawl
ENGAGE
D SIDE VIEW
No s
pace
between
Ratchet Pawl
and
Cable Drum
ENGAGED
UNDERNE
A
T
H VIEW
Spac
e between Ratchet P
awl
and C
able Drum
non-indicates engage
ment
Cab
le Drum
Ratchet Pawl
DISE
NGA
GED
SIDE VIEW
No s
pace
betwe
en
Ratc
het Pawl and
DISENGA
GED U
NDERNEA
TH VIEW
UPPER
POSI
TION
LOW
ER POSITION
LOW
ER POSITION
SIDE VIEW
UPPER POSI
TION
SIDE VIEW
Ratc
het
Pawl
in Lower
Position
Ratc
het Pawl
in U
pper Po
sition
Use these Illus
tration, in c
onj
unction with the In
structions on the other
side of
this label.
WARNING
Rachet Bracket is under
EXTREME SPRING
TENSION
.
To avoid possible severe or
fatal injury,
DO NOT
remove
fasteners
from ratchet bracke
t
until spring(s) are fully
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions
/owners
manual.
DO NOT REMOVE THI
S TAG.
Cable
Drum
No
space
betwee
n R
atchet
Paw
l a
nd Cable Drum
ind
icate
s engagement
Cable D
rum
Ratch
et Pawl
ENG
AGE
D SIDE
VIEW
No
space
betwee
n
Rat
chet Pawl
and
Cable Drum
ENGAG
ED UNDE
R
NE
A
T
H VIEW
Space
between Ratchet Pawl
and Cable Drum
non-indic
Cable Drum
Ratch
et Pawl
DISE
NGAGED S
IDE V
IEW
No space between
Rat
chet Pawl
and
DISE
NGAGED U
NDERNE
A
TH VIEW
UPPER
POS
ITION
Use
the
se Illustration,
in co
njunction w
ith the Instruct
ions
on the other side of
this l
abel.
WARNING
Rachet Br
acket is
under
EXTREM
E SPRING
TEN
SION
.
To avoid possible
severe or
fatal injur
y,
DO NOT
re
move
fasteners
from rat
chet
bracket
until spr
ing(
s) a
re full
y
wnwo
und.
To saf
ely
unwi
nd spring(s)
read
and fol
low t
he directio
ns in the
inst
allati
on instructions/owners
manual.
DO NOT RE
MOVE THIS TAG
.
18
Tools Needed:
Power Drill
End Brackets
IMPORTANT: WARNING TAGS MUST BE
SECURELY ATTACHED TO BOTH END
BRACKETS.
SPLINES
GROOVE
DISCONNECT
CABLE GUIDE
HOLE
7/16” Socket
Driver
1/2” Wrench
Step Ladder
End brackets are right and left hand.
You can identify the right hand end
bracket by the disconnect cable guide
hole in the top of the bracket.
Beginning with either side, slide the end
bracket onto the winding shaft so that
the grooves in the ratchet wheel fit onto
the winding shaft splines.
Secure end bracket to the jamb using
(1) 5/16” x 2” hex head lag screw and
(1) 5/16”-18 x 3/4” carriage bolt and
hex nut.
NOTE: Install carriage bolt and hex nut
first then apply lag into header.
Repeat for other end bracket.
RATCHET
WHEEL
WINDING
SHAFT
RIGHT END
BRACKET
TEETH
POINTING
UPWARD
WARNING
TAG
RIGHT END
BRACKET
INSTALLATION
BLACK TOOTH
5/16” X 2”
HEX HEAD LAG
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5/16”-18 x 3/4”
CARRIAGE BOLT
5/16”-18 HEX NUT
21
Page 22
19
Securing Center Bracket
Assembly
Tools Needed:
Power Drill
7/16” Socket
Driver
3//16” Drill Bit
Step Ladder
NOTE: If you are not installing the
idrive® opener on your garage door, you
must install the center bracket bushing
assembly, follow these instructions.
To locate the center bracket, mark the
header halfway between the flagangles
and level the TorqueMaster® spring
tube. Drill 3/16” pilot holes into header
for the lag screws. Fasten the metal
bracket to the header using
(2) 5/16” X 2” lag screws.
CENTER
BRACKET
BUSHING
ASSEMBLY
(2) 5/16” X 2” HEX
HEAD LAG SCREWS
22
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Page 23
20
Securing Door
for Spring Winding
Tools Needed:
Vice Clamp
Place vice clamps onto both vertical
tracks just above the third roller. This is
to prevent the garage door from raising
while winding counterbalance springs.
WARNING
FAILURE TO PLACE VICE CLAMPS
ONTO VERTICAL TRACK CAN
ALLOW DOOR TO RAISE AND
CAUSE SEVERE OR FATAL
INJURY.
PLACE
VICE
CLAMPS
ABOVE
3RD
ROLLER
INSTALLATION
VICE CLAMPS
ATTACHED TO
INNER RAIL
OF TRACK
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TRACK
23
Page 24
21
No space between Ratchet
Pawl and Cable Drum
indicates engagement
Cable Drum
Ratchet Pawl
ENGAGED SIDE VIEW
ENGAGED UNDERNEATH VIEW
Use these Illustration, in conjunction with the Instructions on the other side of
this label.
WA RNING
Rachet
Bracket is
u
nder
EXTREME SPRING
TENSION
.
To avoid possible sever
e or
fatal injury,
DO NOT
remove
fasteners from ratchet bracket
until spring(s) are fully
wnwound.
To safely unwind spr
ing(s)
read
and follow
the directions in the
installation instructions
/owners
manual.
DO NOT
REMOVE T
HIS TAG.
Cable Adjustment
1/2 WRAP SHOWN
FIRST
GROOVE
Tools Needed:
Pliers
Flat Tip
Screwdriver
Step Ladder
Starting on the right hand side, rotate
the cable drum until the set screw
faces directly away from the header.
Torque tube cam peak should be
pointing straight up.
Loosen the set screw no more than
1/2 turn. Using locking pliers, pull on
the end of the cable to remove all cable
slack.
IMPORTANT: A MINIMUM OF A
1/2 WRAP IS REQUIRED FOR
PROPER DOOR OPERATION.
CABLE MUST BE TAUT AND IN
THE SPIRAL, OR THREAD, OF THE
CABLE DRUM.
Check to ensure the cable is aligned
and seated in the first groove of the
cable drum. Snug the set screw, and
then tighten an additional 1-1/2 turns.
Left side will be adjusted in Step 23.
IMPORTANT: ENSURE THE
CABLE IS ALIGNED AND SEATED
IN THE FIRST GROOVE OF THE
CABLE DRUM PRIOR TO WINDING
SPRINGS.
CAM PEAK
1-1/2 WRAP SHOWN
CAM PEAK
CUT CABLE HERE
PLIERS
SET SCREW
SET SCREW
SET SCREW
CABLE DRUM HOLE
6”
RIGHT HAND DRUM
FIRST
GROOVE
RIGHT HAND DRUM
Measure approximately 6” of cable and
cut off excess cable. Insert end of cable
in hole of cable drum.
NOTE: Illustrations show the right hand
TorqueMaster
®
Plus drum, left hand
TorqueMaster® Plus drum is
symmetrically opposite.
24
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Page 25
Winding Springs
22
Tools Needed:
Ratchet Wrench
5/8” Socket
3” Extension
Gloves
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WARNING
IT IS RECOMMENDED THAT LEATHER
GLOVES BE WORN WHILE WINDING
THE TORQUEMASTER
FAILURE TO WEAR GLOVES MAY CAUSE
INJURY TO HANDS.
Double check to ensure the counterbalance
cable is aligned in the first groove of the cable
drum as shown in Step 21.
Staring with the right hand side, place a mark
on winding shaft (or socket) and end bracket.
Turn the pawl knob on the end bracket to the
upper position.
IMPORTANT: USING A RATCHET WITH A 16 MM
(5/8”) SOCKET (NOTE: A 76 MM (3”) EXTENSION
IS ALSO RECOMMENDED FOR ADDED
CLEARANCE FROM THE HORIZONTAL ANGLE.),
WIND THE SPRING BY ROTATING THE WINDING
SHAFT COUNTER CLOCKWISE, WHILE WATCHING
THE MARK ON THE WINDING SHAFT. DO NOT
USE IMPACT GUN TO WIND SPRING(S).
IMPORTANT: PAWL KNOB MUST BE IN UPPER
POSITION TO ADD/ REMOVE REQUIRED NUMBER
OF SPRING TURNS.
After 2-3 turns, remove the ratchet and
adjust the cable on the left side. Ensure the
cables are in the first groove and the cable
drums, as shown in Step 21.
NOTE: Single spring applications require
no spring winding of the left hand side but
need cable tension adjustments.
IMPORTANT: COUNTERBALANCE CABLE
TENSION MUST BE EQUAL ON BOTH SIDES
PRIOR TO FULLY WINDING SPRINGS.
SEE THE SPRING TURN CHART FOR THE
REQUIRED NUMBER OF TURNS:
For single spring applications:
Return to the right hand and continue
winding the spring to the required number
of turns for your door. Place pawl knob in
lower position.
For double spring applications:
Place a mark on the winding shaft and end
bracket. Place the ratchet with 5/8” socket
onto the left hand winding shaft end. To
wind the spring, rotate the winding shaft
clockwise, while watching the mark on the
winding shaft.
Rotate the winding shaft to the required
number of turns for your door. Then return
to the right hand side and wind the right
hand spring to the required number of
turns. Place pawl knob in lower position on
both sides.
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
®
PLUS SPRINGS.
Door Height Spring Turns Door Height Spring Turns
6’-0” 14 7’-0” 16
6’-3” 14-1/2 7’-3” 16-1/2
6’-5” 15 7’-6” 17
6’-6” 15 7’-9” 17-1/2
6’-8” 15-1/2 8’-0” 18
6’-9” 15-1/2
END BRACKET
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.
RECOMMENDED SPRING TURNS
END BRACKET
MARKS
RATCHET
5/8” SOCKET
3”
EXTENSION
PAWL KNOB IN UPPER
POSITION
WARNING
INSTALLATION
25
Page 26
Spring Turns
Door Height Spring Turns
(6’ - 0”) 14
(6’ - 3”) 14 - 1/2
(6’ - 5”) 15
(6’ - 6”) 15
(6’ - 8”) 15 - 1/2
(6’ - 9”) 15 - 1/2
(7’ - 0”) 16
(7’ - 3”) 16 - 1/2
(7’ - 6”) 17
(7’ - 9”) 17 - 1/2
(8’ - 0”) 18
Number of Installed Spring Turns
Winding Springs Continued...
END BRACKET
Tools Needed:
IMPORTANT: MARK NUMBER OF SPRING
TURNS ON TORQUEMASTER® PLUS END
BRACKET WARNING TAG.
NOTE: Since total turns to balance door
can deviate from SPRING TURN CHART
values by ± 1/2 turn, adjustments to the
recommended number of turns may be
required AFTER rear hangers assembly is
completed.
IMPORTANT: HOLD THE DOOR DOWN TO
PREVENT IT FROM RISING UNEXPECTEDLY
IN THE EVENT THE SPRING WAS
OVERWOUND AND CAUTIOUSLY REMOVE
VICE CLAMPS FROM VERTICAL TRACKS.
Do not raise the door until horizontal tracks
are secured at the rear, as outlined in step
24.
WARNING
RAISING DOOR FURTHER CAN
RESULT IN DOOR FALLING AND
CAUSE SEVERE OR FATAL INJURY.
PAWL KNOB IN LOWER
BACK OF TORQUEMASTER
POSITION
®
PLUS END BRACKET WARNING TAG
LOCATION FOR
MARKING NUMBER
OF INSTALLED
SPRING TURNS
23
None
Drum Wrap Installation
Starting with the left hand side, align
the counterbalance cable with one of
the slots in the drum wrap. Slide the
DRUM
(LEFT HAND)
DRUM WRAP
(LEFT HAND)
drum wrap over the drum until the tabs
snap between the cable drum and the
ratchet gear. Repeat for right hand side.
IMPORTANT: RIGHT AND LEFT HAND
ARE ALWAYS DETERMINED FROM
INSIDE THE GARAGE LOOKING OUT.
COUNTERBALANCE
CABLE
TABS
26
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GROOVE
IN DRUM
Page 27
24
Rear Support
DOOR IN THE
UP POSITION
Tools Needed:
Ratchet Wrench
1/2” Socket
1/2” Wrench
(2) Vice Clamps
Tape Measure
Level
Hammer
Step Ladder
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
is not yet supported.
track
WARNING
RAISING DOOR FURTHER CAN
RESULT IN DOOR FALLING AND
CAUSE SEVERE OR FATAL INJURY.
Clamp a pair of vice clamps on the
vertical tracks just above the second
roller on one side, just below the second
roller on the other side. This will prevent
the door from raising or lowering while
installing the rear support.
Using perforated angle, 5/16” x 1-5/8”
hex head lag screws and 5/16” bolts
with nuts (may not be supplied),
fabricate rear support for horizontal
tracks. Attach horizontal tracks to
the rear supports with 5/16”-18 x
1-1/4” hex bolts and nuts (may not be
supplied). Horizontal tracks must be
level and parallel within 3/4” maximum
of door edge.
VICE
CLAMPS
VERTICAL
TRACK
INSTALLATION
WARNING
KEEP HORIZONTAL TRACK
PARALLEL AND WITHIN 3/4”
MAXIMUM OF DOOR EDGE,
OTHERWISE DOOR COULD FALL,
RESULTING IN SEVERE INJURY
OR DEATH.
IMPORTANT: DO NOT SUPPORT THE
WEIGHT OF THE DOOR ON ANY PART OF
THE HORIZONTAL TRACK HANGER THAT
CANTILEVERS 4” OR MORE BEYOND A
SOUND FRAMING MEMBER.
NOTE: If rear supports are to be
installed over drywall, use 5/16” x 2”
hex head lag screws.
NOTE: If an idrive® opener is installed,
position horizontal tracks one hole
above level when securing it to rear
supports.
NOTE: 26” angle must be attached
to sound framing members and nails
should not be used.
Permanently attach the weather
seal to both door jambs and header.
(Temporarily attached in PREPARING
THE OPENING on page 6.) Avoid pushing
weather seal too tightly against face of
door.
Now, lift door and check it’s balance.
Adjust, if door lifts by itself (hard to pull
down) or if door is difficult to lift (easy to
pull down). Anytime spring adjustments
are made, ratchet pawl knob must be
in the upper position to add/remove
required number of spring turns. To
adjust springs, only add or remove a
maximum of 3/10 of a turn (three teeth
3/4”
TOP SECTION
3/4”
Door Edges
Horizontal Tracks
Horizontal
Tracks
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27
Page 28
Rear Support Continued...
SOUND FRAMING MEMBERS
Tools Needed:
of ratchet wheel) at a time. Both sides
need to be adjusted equal on double spring
doors.
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.
Add Spring Tension: The ratchet wheel is
made of 10 teeth. To add spring tension,
ensure the ratchet and socket is set so that
PERFORATED
ANGLE
HORIZONTAL TRACK
SOUND FRAMING MEMBERS
24” MAX.
PERFORATED ANGLE
- BOLTED USING (2) 5/16”
X 1-5/8” HEX HEAD LAG
SCREWS TO CEILING
MEMBER AND PARALLEL
TO WIDTH OF DOOR. SPACE
LAG SCREWS NO FURTHER
THAN 24” APART
BOLT MUST EXTEND INTO
THE TRACK TO SERVE AS
A ROLLER STOP
it will tighten counter clockwise on the right
hand side, and clockwise on the left hand
side. Place the ratchet with 5/8’ socket
onto the winding shaft, pull down to add
3/10 of a turn. Watch as three teeth of the
ratchet wheel pass over the pawl, creating
three “clicks”.
Remove Spring Tension: To remove spring
tension, ensure the ratchet and socket is
set so that it will tighten counter clockwise
on the right hand side and clockwise on
the left hand side. It is recommended that
a regular 5/8” wrench be used. Place the
wrench onto the winding shaft. Pull down
on the wrench to relieve pressure between
the pawl and the ratchet wheel. Push in on
the pawl to allow the three ratchet wheel
teeth to pass by the pawl, as you carefully
allow the wrench to be rotated upward by
the spring tension. Release the pawl to
PERFORATED
ANGLE
HORIZONTAL TRACK
PERFORATED ANGLE
PERFORATED ANGLE - BOLTED
USING (2) 5/16” X 1-5/8” HEX
24” MAX.
HEAD LAG SCREWS TO CEILING MEMBERS AND PARALLEL
TO WIDTH OF DOOR. ATTACH
VERTICAL PERFORATED ANGLE
BETWEEN THE (2) 5/16” X 15/8” HEX HEAD LAG SCREWS,
SECURING PERFORATED
ANGLE TO CEILING MEMBERS
BOLT MUST EXTEND INTO
THE TRACK TO SERVE AS
A ROLLER STOP
allow it to engage with the ratchet wheel.
IMPORTANT: BE PREPARED TO HOLD THE
FULL TENSION OF THE SPRING.
IMPORTANT: DO NOT ADD OR REMOVE
MORE THAN 1 SPRING TURNS (1 SPRING
TURN EQUALS 10 TEETH ON RATCHET
WHEEL) FROM THE RECOMMENDED
WEATHER
NUMBER OF TURNS SHOWN ON THE
SPRING TURN CHART.
JAMB
If the door still does not operate easily,
lower the door into the closed position,
UNWIND SPRING (S) COMPLETELY, and
recheck the following items:
1.) Check the door for level.
(3) 5/16”
BOLTS & NUTS
PERMANENTLY ATTACHED
WEATHER SEAL
2.) Check the TorqueMaster® spring tube
and flagangles for level and plumb.
3.) Check the distance between the
flagangles - must be door width
plus 3-3/8” to 3-1/2”.
4.) Check the counterbalance cables
for equal tension - adjust if necessary.
5.) Rewind the spring(s).
6.) Make sure door isn’t rubbing on jambs
If an idrive was installed and you have
completed your rear support installation,
refer to the idrive Installation Instructions
and Owner’s Manual to complete your
idrive installation.
28
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SEAL
Page 29
TorqueMaster® Plus Reset
Instructions
ENGAGEMENT SIDE VIEW
Tools Needed:
5/8” Socket
Ratchet Wrench
3” Extension
Vice Clamps
(Pair)
WARNING
READ THESE INSTRUCTIONS
CAREFULLY BEFORE
ATTEMPTING TO RESET THE
TORQUEMASTER® PLUS SYSTEM.
IF IN QUESTION ABOUT ANY
OF THE PROCEDURES, DO NOT
PERFORM THE WORK. INSTEAD,
HAVE A TRAINED DOOR SYSTEMS
TECHNICIAN RESET THE SYSYEM.
This door is equipped with a
TorqueMaster® Plus system, which
provides a safety feature that prevents
the door from rapidly descending in
case of spring failure or forceful manual
operation. Signs of an activated system
on a dual spring system: Door opens,
but will not close; door makes a distinct
“clicking” noise upon opening. If the
system is activated, carefully follow
the reset instructions below or refer
to the door’s Installation Instructions
and Owner’s Manual to reset the
TorqueMaster
NOTE: Proceed with TorqueMaster Plus
Reset Instructions if it is absolutely
necessary to open the garage door,
contact your nearest qualified WayneDalton repair center for repairs.
®
Plus system.
RATCHET
PAWL
DRUM PAWL
ENGAGEMENT UNDERNEATH VIEW
NO SPACE BETWEEN
DRUM PAWL AND
CABLE DRUM
NON-ENGAGEMENT SIDE VIEW
CABLE DRUM
NO SPACE BETWEEN
DRUM PAWL AND CABLE
DRUM
INDICATES ENGAGEMENT
INSTALLATION
RESETTING THE ANTI-DROP DEVICE
1. First, locate and visual inspect the
TorqueMaster® Plus end brackets to
determine if the system has engaged
(see illustration).
NOTE: If the TorqueMaster® Plus system
CABLE DRUM
has not engaged, do not complete the
following step.
If the system has engaged, follow these
steps to reset the system:
2. Disengage opener (if installed) by
NON-ENGAGEMENT UNDERNEATH VIEW
DRUM PAWL
SPACE BETWEEN DRUM PAWL
AND CABLE DRUM
NON-INDICATES ENGAGEMENT
pulling or placing emergency disconnect
in the manual operated position.
3. With the door in the open or partially
open position, clamp vice grips on both
vertical tracks just below the bottom
section roller.
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SPACE BETWEEN
DRUM PAWL AND
CABLE DRUM
29
Page 30
TorqueMaster® Plus Reset
Instructions Continued...
Tools Needed:
4. Now is a good time to remove vehicles
or items from garage to provide clear
access to end brackets.
5. Flip the ratchet pawl knob on both
end brackets to the upper position (see
illustration).
6. Raise door 2”-3” and then lower
door. Repeat process until anti-drop
device resets (see disengaged system
illustration on previous page).
IMPORTANT: BE PREPARED TO SUPPORT
THE TOTAL WEIGHT OF THE DOOR.
7. Cautiously remove the vice clamps
from the vertical tracks. With assistance,
lower the door.
8. Check for spring tension. Starting on
the right hand side, place a ratchet and
5/8” socket on the TorqueMaster® Plus
winding shaft (see illustration). Ensure
ratchet is set so that it will tighten
counter clockwise on the right hand side,
and clockwise on the left hand side (if
applicable). If tension is present, remove
the ratchet and check the left hand side
(if applicable). If spring(s) have tension,
proceed to Balancing Door; if no spring
tension is present, contact a qualified
door systems technician to replace the
spring(s).
LOWER POSITION
PLACE VICE CLAMPS
BELOW BOTTOM SECTION
ON BOTH VERTICAL TRACK
UPPER POSITION
WARNING
TO AVOID POSSIBLE INJURY, HAVE A
PAWL KNOB IN LOWER
POSITION
PAWL KNOB IN UPPER
POSITION
TRAINED DOOR SYSTEM TECHNICIAN
MAKE ADJUSTMENTS/REPAIRS TO
CABLES, SPRING ASSEMBLIES AND
OTHER HARDWARE.
BALANCING DOOR
Lift door and check its balance. Adjust
END BRACKET
spring(s), if door lifts by itself (hard to pull
down) or if door is difficult to lift (easy to
pull down). Anytime spring adjustments
are made, ratchet pawl knob must be in
the upper position (see illustration).
An unbalanced door such as this can
cause idrive® or TorqueMaster® Plus
operation problems. To adjust spring(s),
only add or remove a maximum of 3/10
of a turn (three teeth of ratchet wheel) at
a time. Both sides need to be adjusted
PAWL
3” EXTENSION
30
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RATCHET
WITH 5/8”
SOCKET
Page 31
TorqueMaster® Plus Reset
Instructions Continued...
Tools Needed:
equally on double spring doors.
NOTE: Single spring applications require
no spring winding on left hand side.
Clamp a pair of vice clamps on the
vertical tracks just above the second
PLACE VICE CLAMPS
ABOVE 3RD ROLLER ON
BOTH VERTICAL TRACKS
roller on one side and just below the
second roller on the other side. This
will prevent the door from raising or
lowering while adjusting the spring(s).
WARNING
VICE CLAMPS
ATTACHED TO
INNER RAIL
OF TRACK
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.
LOWER POSITION
UPPER POSITION
To Add Spring Tension:
The ratchet wheel is made of 10 teeth.
To add spring tension, ensure the
ratchet and socket is set so that it will
tighten counter clockwise on the right
hand side, and clockwise on the left
hand side. Place the ratchet with 5/8”
socket onto the winding shaft, pull down
to add 3/10 of a turn. Watch as three
teeth of the ratchet wheel pass over the
ratchet pawl, creating three “clicks”.
To Remove Spring Tension:
To remove spring tension, ensure the
ratchet and socket is set so that it will
tighten counter clockwise on the right
hand side and clockwise on the left
hand side. It is recommended that a
regular 5/8” wrench be used. Place
PAWL KNOB IN LOWER
POSITION
PAWL KNOB IN UPPER
POSITION
the wrench onto the winding shaft.
Pull down on the wrench to relieve
pressure between the ratchet pawl
and the ratchet wheel. Push in on the
pawl to allow the three ratchet wheel
teeth to pass by the ratchet pawl, as
you carefully allow the wrench to be
rotated upward by the spring tension.
Release the pawl to allow ratchet pawl
to engage with the ratchet wheel.
END BRACKET
RATCHET
WITH 5/8”
SOCKET
Remove the vice clamps from the
vertical tracks, re-check doors balance
and adjust if necessary. When door is
balanced and adjusted properly, place
the ratchet pawl knobs in the active
position (lower position).
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PAWL
3” EXTENSION
TRACK
INSTALLATION
31
Page 32
Side Lock
Tools Needed:
Power Drill
7/16” Socket
Driver
Tape Measure
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.
NOTE: After completing this step,
continue with step 7 on page 12.
1/8”
(4) 1/4”- 20 X 11/16”
SELF DRILLING SCREWS
Tools Needed:
Power Drill
1/8” Drill Bit
Pull Rope
WARNING
DO NOT INSTALL PULL ROPES
ON DOORS WITH ELECTRIC
OPERATORS. CHILDREN MAY
BECOME ENTANGLED IN THE
ROPE CAUSING SEVERE OR
FATAL INJURY.
Measure and mark the jamb
approximately 48” to 50” (1220 to 1270
mm) from floor on the right or left side
of door. Drill 1/8” pilot hole for No. 6
screw eye. Install the No. 6 screw eye.
Tie the pull rope to the No. 6 screw eye
and to the bottom bracket as shown.
NO. 6 SCREW EYE
PULL ROPE
PULL ROPE
BOTTOM
BRACKET
32
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Page 33
Step Plate
STEP PLATE OUTSIDE
Tools Needed:
7/16” Drill Bit
Power Drill
Make one mark 1” (25 mm) up from
the center of bottom edge of the bottom
section and another mark 2-3/16” (56 mm)
up from the first mark.
Drill a 7/16” (11 mm) hole through the
section at each mark and insert the outside
step plate.
Loosely fasten step plate slide to base with
(1) 1/4” - 20 x 5/8” carriage bolt and nut.
Align inside step plate holes and fasten
from inside using the #8 screws provided.
Install one #8 x 3/4” screw in the bottom
step plate hole. The screw in the top hole
varies with door models.
Use the screw size shown below for your
model door.
a) #8 x 3/4” screw for Model 9100
b) #8 x 1” screw Model 9600/9400
Tighten 1/4”-20-5/8” carriage bolt and
nut.
2-3/16”
1/4” - 20 X 5/8”
CARRIAGE BOLT
STEP PLATE
SLIDE
1”
STEP PLATE
BASE
STEP PLATE INSIDE
ASSEMBLED
STEP PLATE
#8 SCREWS
HEX NUT
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OPTIONAL INSTALLATION
33
Page 34
Trolley Installation for
Standard Lift
DETERMINE THE WAYNE-DALTON
TRACK RADIUS BEING USED:
LEVEL
HIGH ARC
Measure the curved ends of the horizontal track to determine
if you have a 12” or 15” radius horizontal track, as shown
in FIG. 2.1. Determine center line of door. Mark vertical line
at this point, on the header wall. Raise the door slightly until
the top section reaches the highest point of travel (high arc).
Using a level, mark this high arc point of travel on the header
wall, intersecting the vertical center line, as shown in FIG.
2.2 through 2.3. Hold the wall bracket’s bottom edge to the
appropriate 1/2” - 1” (room permitting) above of the high
arc line and centered on the vertical line, as shown in FIG.
2.3. Spot the wall brackets mounting holes on the header
wall and then refer to your garage door operator manual
for pre-drilling and securing the wall bracket to header.
Using the OPERATOR HOOK-UP CHARTS, refer to referenced
illustrations in FIG. 2.4 through FIG. 2.5 for correct arm hookup from trolley to operator bracket.
NOTE: Refer to your operator manual for specific details on
how to assembly the curved and straight arm, as shown in
FIG. 2.4 through FIG. 2.5.
NOTE: Depending on your setup, you may or may not have to
cut straight arm to accomplish trolley settings, as shown in
FIG. 2.4 through FIG. 2.5.
HORIZONTAL
TRACK
12” OR 15”
FIG. 2.1
TYPICAL 1/2” - 1” ABOVE HIGH ARC
HIGH ARC
LINE
FROM
STEP 12
TORQUEMASTER
COUNTERBALANCE
VERTICAL
CENTER LINE
HEADER
FIG. 2.3
STRAIGHT
ARM
®
CURVED
ARM
FIG. 2.2
CURVED
ARM
FIG. 2.4
TOP
SECTION
STRAIGHT
ARM
CUT STRAIGHT
ARM TO
ACCOMPLISH
TROLLEY
SETTING
CUT STRAIGHT ARM
TO ACCOMPLISH
TROLLEY SETTING
FIG. 2.5
OPERATOR HOOK-UP CHART STANDARD LIFT FOR 12” RADIUS
OPERATOR MODELS TYPE OF ARM BEING USED
QUANTUM/CLASSIC CURVED / STRAIGHT FIG. 2.5
LINEAR STRAIGHT / CURVED FIG. 2.4
LIFTMASTER
(SEARS)
GENIE CURVED / STRAIGHT FIG. 2.5
OPERATOR HOOK-UP CHART STANDARD LIFT FOR 15” RADIUS
OPERATOR MODELS TYPE OF ARM BEING USED
QUANTUM/CLASSIC CURVED / STRAIGHT FIG. 2.5
LINEAR STRAIGHT / CURVED FIG. 2.4
LIFTMASTER
(SEARS)
GENIE CURVED / STRAIGHT FIG. 2.5
CURVED / STRAIGHT FIG. 2.5
CURVED / STRAIGHT FIG. 2.5
REF. ILLUSTRATIONS
ABOVE
REF. ILLUSTRATIONS
ABOVE
34
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Page 35
Trolley Installation for
Low Headroom
Determine center line of door. Mark vertical line at this
point, on the header wall. Raise the door slightly until the
top section reaches the highest point of travel (high arc).
Using a level, mark this high arc point of travel on the header
wall, intersecting the vertical center line, as shown in FIG.
3.1 through 3.2. Hold the wall bracket’s bottom edge to the
appropriate 1/2” - 1” (room permitting) above of the high
arc line and centered on the vertical line, as shown in FIG.
3.2. Spot the wall brackets mounting holes on the header
wall and then refer to your garage door operator manual
for pre-drilling and securing the wall bracket to header.
Using the OPERATOR HOOK-UP CHARTS, refer to referenced
illustrations in FIG. 3.3 through FIG. 3.4 for correct arm hookup from trolley to operator bracket.
NOTE: Refer to your operator manual for specific details on
how to assembly the curved and straight arm, as shown in
FIG. 3.3 through FIG. 3.4.
NOTE: Depending on your setup, you may or may not have to
cut straight arm to accomplish trolley settings, as shown in
FIG. 3.3 through FIG. 3.4.
LEVEL
TOP
SECTION
HIGH ARC
FIG. 3.1
FIG. 3.3
LOW
HEADROOM
TRACK
STRAIGHT
ARM
TYPICAL 1/2” - 1”
ABOVE HIGH ARC
HIGH ARC
LINE
FROM
STEP 12
FIG. 3.2
CURVED
ARM
FIG. 3.4
TORQUEMASTER
COUNTERBALANCE
VERTICAL
CENTER LINE
HEADER
CUT STRAIGHT
ARM TO
ACCOMPLISH
TROLLEY
SETTING
®
OPERATOR HOOK-UP CHART FOR LOW HEADROOM
TYPE OF ARM BEING USED
OPERATOR
MODELS
QUANTUM/
CLASSIC
LINEAR STRAIGHT FIG. 3.3 N/A N/A
LIFTMASTER
(SEARS)
GENIE
PREFERRED
HOOKUP
CURVED /
STRAIGHT
CURVED /
STRAIGHT
CURVED /
STRAIGHT
REF.
ILLUSTRATIONS
ABOVE
FIG. 3.4 STRAIGHT FIG. 3.3
FIG. 3.4 STRAIGHT FIG. 3.3
FIG. 3.4 STRAIGHT FIG. 3.3
OPTIONAL
HOOKUP
REF. ILLUSTRATIONS
ABOVE
OPTIONAL INSTALLATION
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35
Page 36
Tools Needed:
Trolley Operator
WARNING
OPERATOR MUST BE TESTED
AT TIME OF INSTALLATION
AND MONTHLY THEREAFTER
AS DESCRIBED IN YOUR
INSTALLATION INSTRUCTIONS
AND OWNER’S MANUAL, TO
ENSURE THAT DOOR SAFETY
FEATURES FUNCTION. FAILURE
TO TEST OR MAKE ANY
NECESSARY ADJUSTMENTS OR
REPAIRS, CAN RESULT IN SEVERE
OR FATAL INJURY.
OPERATOR RAIL
SUITABLE MOUNTING
SURFACE 2 X 6
LUMBER MINIMUM
DOOR ARM TO
OPERATOR BRACKET
HEADER
OPERATOR
RAIL
1. Install operator rail 1/2” to 1-1/2”
(13 - 38 mm) above high arc of top
section of the door.
2. Mount operator to ceiling so that
1” to 1-1/2” (25 - 38 mm)
clearance is maintained between
trolley rail and top section when
door is fully open (trolley rail will
slope down towards rear).
3. Attach door arm to operator bracket.
4. Attach operator rail to suitable
mounting surface, 2 x 6 lumber
minimum.
5. Attach operator to ceiling using
perforated angle.
IMPORTANT: ANGLES MUST BE
SECURELY ATTACHED TO SOUND
FRAMING MEMBER(S).
OPERATOR
OPERATOR
BRACKET
OPERATOR
BRACKET TABS
5/16” X 1-1/4”
PERFORATED
ANGLE
HAIRPIN
COTTER
DOOR
ARM
CLEVIS PIN
TOP VIEW
OPERATOR
BRACKET TABS
DOOR ARM
HAIRPIN COTTER
(OUTSIDE OF
OPERATOR
BRACKET TAB)
FRAMING MEMBERS
PERFORATED ANGLE
36
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Page 37
Cleaning
Cleaning Your Garage Door
IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR 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. To maintain an aesthetically pleasing finish of the garage door, a
periodic washing of the garage door is recommended.
The following cleaning solution is recommended
A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into five gallons of warm water will
aid in the removal of most dirt.
NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.
NOTE: Be sure to clean behind weather stripping on both sides and top of door.
CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.
GLASS CLEANING INSTRUCTIONS
Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.
ACRYLIC CLEANING INSTRUCTIONS
Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on
particles. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will scratch
the acrylic glazing. Dry glazing with a clean damp chamois.
NOTE: DO NOT USE any window cleaning fluids, scouring compounds, gritty cloths or solvent-based cleaners of any kind.
Painting
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.
Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or No. 400 sand
paper to create a smoother surface. Care must be taken to not expose the substrate under the paint. Once the substrate is exposed, the
likelihood for rusting is greatly increased.
If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed area lightly and paint with a high quality metal
primer, specifically intended for galvanized surfaces, to protect the area from corrosion. Allow for drying time on primer can label before
applying topcoat. The surface of the factory-applied finish, that is being painted, must not be too smooth, or the paint will not adhere to
it. It is advisable to test in an inconspicuous area, to evaluate adhesion. If poor adhesion is observed, surface preparation for painting the
factory-applied finish must be repeated until desired results are achieved. Again, care must be taken to not expose the substrate under
the paint.
Painting
After surface has been properly prepared, it must be allowed to dry thoroughly, and then coated immediately with premium quality latex
house paint. Follow paint label directions explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate is
exposed and not properly primed, painting with latex paint may cause accelerated rusting of the steel in the exposed area.
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com
MAINTENANCE
37
Page 38
Painting Continued....
NOTES:
1. Repainting of finish painted steel doors cannot be warranted, as this condition is totally beyond the door manufacturer’s control.
2. Consult a professional coatings contractor if in doubt about any of the above directions.
3. Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers. Pay particular
attention to acceptable weather and temperature conditions in which to paint.
38
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
Page 39
Lifetime Limited Warranty
Models 9100, 9400, 9600
Subject to the terms and conditions contained in this Lifetime Limited Warranty, Wayne-Dalton Corp. (“Manufacturer”) warrants the sections of the door, which is described
at the top of this page, for as long as you own the door against:
(i) The door becoming inoperable due to rust-through of the steel skin from the core of the door section, due to cracking, splitting, or other
deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.
(ii) Peeling of the original paint on the door as a result of a defect in the original paint or in the application of the original paint coating, in cases
where the door sections and the original paint: (a) have not been subjected to adverse atmospheric conditions or contaminates (such as salt water
or other marine environment, or to toxic or abrasive substances, including those in the air); (b) have been maintained in compliance with
Manufacturer’s recommendations; and (c) have not been subject to physical abrasion, impacted by a hard object, or punctured (including
without limitation “paint rub” occurring in metal to metal contact and movement).
The Manufacturer warrants the garage door hardware (except springs) and the tracks of the above-described door, for as long as you own the door, against
defects in material and workmanship, subject to all the terms and conditions below.
The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Lifetime Limited Warranty against defects in
material and workmanship for a period of ONE (1) YEAR from the date of installation.
The Manufacturer warrants the factory-applied finish and the factory attached stiles against fading and cosmetic changes from the time of installation for TWO
(2) YEARS. If the door is re-stained or re-painted, the TWO (2) YEARS warranty for the factory-applied finish is void. The Model 9400 factory attached stiles are warranted
against peeling, cracking, chalking, or delamination from the time of installation for TWO (2) YEARS.
After a period of TWENTY (20) YEARS, from time of installation, replacement of Lifetime Limited Warranty materials will be pro-rated at 50 per cent of Manufacturer’s published list pricing at time of claim, and you must pay this amount.
This Limited Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as his/her
primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or to installations on rental
property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the premises is sold), nor does it extend
benefits to any other person. As a result this warranty does NOT apply to any person who purchases this product from someone other than an authorized Wayne-Dalton
dealer or distributor.
The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its components, abuse, damage from corrosive fumes or substances, salt spray or saltwater air, fire, Acts of God, failure to properly maintain the door, or attempt to use the door, its
components or related products for other than its intended purpose and its customary usage. This Limited Warranty does not cover ordinary wear. This Limited Warranty
will be voided if the original finish is painted over, unless Manufacturer’s preparation and painting instructions are followed explicitly. This Limited Warranty will be voided if
any holes are drilled into the door, other than those specified by the Manufacturer.
THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS ACT. NO WARRANTIES, EXPRESS OR IMPLIED (INCLUDING
BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDER-
SCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY, ABOVE.
• SomeStatesdonotallowlimitationsonhowlonganimpliedwarrantylasts,sotheabovelimitationsmaynotapplytoyou.
Any claim under this Limited Warranty must be made in writing, within the applicable warranty period, to the dealer from which the product was purchased.
Unless the dealer is no longer in business, a written claim to the Manufacturer will be the same as if no claim had been made at all.
At the Manufacturer’s option, a service representative may inspect the product on site, or Buyer may be required to return the product to the Manufacturer at
Buyer’s expense. Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect
and full access to the location of its installation.
If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty, the Manufacturer will repair or replace the defective product.
The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer, subject to applicable law. THE REMEDY WILL COVER ONLY
MATERIAL. THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES, SUCH AS FIELD SERVICE LABOR FOR REMOVAL, INSTALLATION, PAINTING, SHIPPING, ETC.
Any repairs or replacements arranged by Manufacturer will be covered by (and subject to) the terms, conditions, limitations and exceptions of this Limited Warranty; provided, however, that the installation date for the repaired or replaced product will be deemed to be the date the original product was installed, and this Limited
Warranty will expire at the same time as if there had been no defect. If a claim under this Limited Warranty is resolved in a manner other than described in the immediately
preceding paragraph, then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the repaired or replaced portion of the product.
THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy. The liability of the Manufacturer, whether in contract or tort, under warranty, product liability, or otherwise, will not go beyond the Manufacturer’s obligation to repair or replace, at its option, as
described above. THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, including (but not
limited to) damage or loss of other property or equipment, personal injury, loss of profits or revenues, business or service interruptions, cost of capital , cost of purchase or
replacement of other goods, or claims of third parties for any of the foregoing.
• SomeStatesdonotallowtheexclusionorlimitationofincidentalorconsequentialdamages,sotheabovelimitationorexclusionmaynotapplyto
you.
No employee, distributor, dealer, representative, or other person has the authority to modify any term or condition contained in this Limited Warranty or to grant
any other warranty on behalf of or binding on the Manufacturer, and anyone’s attempt to do so will be null and void.
Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer.
The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio, USA, to the extent
permitted by law.
• ThisLimitedWarrantygivesyouspeciclegalrightsandyoumayalsohaveotherrights,whichmayvaryfromStatetoState.
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
39
Page 40
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. Canadian:
2,384,936; 2,477,445; 2,495,175; 2,507,590; 2,530,701; 2,530,74; 2, 2,532,824. Other US and Foreign Patents pending.
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
Thank you for your purchase
40
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