Wayne-Dalton 9605, 9405 Installation Instructions And Owner's Manual

Models 9100 / 9405
/ 9605

E x t E n s i o n s p r i n g

rEsidEntial
low HEadrooM

installation instructions and ownEr’s
Manual

Table Of Contents

Pre-Installation 2

Important Safety Instructions 2

Removing an Existing Door and Preparing the Opening 2

Package Contents 3

Door Section Identification 4

Tools Required 4

Breakdown Of Parts 5
Installation 6
Counterbalance Installation Instructions 9
Optional Installation 13

Door Arm Hookup 13

Trolley Arm Configuration 13

Inside Lock 13

Pull Down Rope 13

Step Plate 13

Maintenance 15

Cleaning Your Garage Door 15

Painting Your Garage Door 15

Maintaining The Finish On Your Garage Door 15

Operation And Maintenance 15

Warranty 17

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

If you need assistance, please call 1-866­569-3799 (press Option 1) and follow the
prompts to contact a customer service
representative. They will be happy to handle
any questions that you may have.

©Copyright 2017

Wayne Dalton, a division of Overhead Door Corporation

IMPORTANT NOTICES!

To avoid possible injury, read and fully understand 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.

This Installation document is available at no charge from:

- Your local Wayne Dalton Sales Center, or

- Online at www.Wayne-Dalton.com, or

- By mailing to: Wayne Dalton, a division of Overhead Door Corporation, P.O. Box
67, Mt. Hope, OH., 44660

361187

REV1_07/21/2017Part Number

WARNING

WARNING

Pre-Installation

Important Safety Instructions

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.
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 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

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, fasteners, counterbalance lift 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.

18. For windloaded doors, the wind performance is achieved via the entire door system

and component substitution is not authorized without express permission by Wayne
Dalton.

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

CAUTION

IF ANY PART OF THE DOOR IS TO BE INSTALLED ONTO PRESERVATIVE­TREATED WOOD, PTFE-COATED OR STAINLESS STEEL FASTENERS MUST BE
OBTAINED AND USED. REPLACEMENT FASTENERS MUST BE OF AT LEAST
EQUAL STRENGTH AND SIZE AS ORIGINAL FASTENERS. IF THE ORIGINAL
FASTENER WAS RED-HEAD, THE REPLACEMENT FASTENER MUST BE RED­HEAD ALSO. CONTACT WAYNE DALTON FOR FASTENER STRENGTH VALUES IF
NEEDED.

WARNING

IMPACT GUNS ARE NOT RECOMMENDED. 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.

IMPORTANT: RIGHT AND LEFT HAND IS DETERMINED INSIDE THE BUILDING LOOKING OUT.

Potential Hazard Effect Prevention

Keep people clear of opening

Could result in Death or

Serious Injury

Moving door

Could result in Death or

Serious Injury

High tension spring

while Door is moving.

Do NOT allow children to play

with the Door Opener.

Do NOT operate a Door that

jams or one that has a broken

spring.

Do NOT try to remove, install,

repair or adjust springs or

anything to which door spring

parts are fastened, such as,
wood blocks, steel brackets,

cables or other like items.

Installations, repairs and

adjustments must be done by

a trained door system techni-

cian using proper tools and

instructions.

Removing an Existing Door

and Preparing the Opening

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

WARNING

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

To avoid possible injury and to insure proper installation, it's highly recommended that you
read and fully understand the complete instructions on removing an Existing Door & Prepar­ing the Opening. These are available for download at www.Wayne-Dalton.com or at your
local Wayne Dalton Sales Center.

IMPORTANT: 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® counterbalance systems. For low headroom applications, the
jambs should extend to the ceiling height. Minimum side clearance required, from the open­ing to the wall, is 3-1/2” (89 mm).

IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD
FOUND NOT TO BE SOUND, MUST BE REPLACED.

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

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

WEATHERSTRIPS (MAY NOT BE INCLUDED):

Depending on the size of your door, you may have to cut or trim the weatherstrips (if neces­sary) to properly fit into the header and jambs.

NOTE: If nailing product at 40°F or below, pre-drilling is required.
NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.
FOR QUICK INSTALL TRACK: For the header, align the weatherstrip with the inside edge

of the header and temporarily secure it to the header with equally spaced nails. Starting
at either side of the jamb, fit the weatherstrip up tight against the temporarily attached
weatherstrip in the header and flush with the inside edge of the jamb. Temporarily secure
the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom
section from falling out of the opening during installation. Equally space nails approximately

2

12” to 18” apart.

Extension Springs

Quick Install flag angles RH/LH (as required

brackets (as required)

3-3/4” Eye bolts

Counterbalance lift cables

cable lift sheaves

cable lift sheaves

(as required)

hex nuts (as required)

Carriage bolts

Track bolts

3/8"-16 x 1-1/2" Truss head bolts

FOR FULLY ADJUSTABLE TRACK: For the header, align the weatherstrip 1/8” to 1/4” inside
the header edge, and temporarily secure it to the header with equally spaced nails. Starting
at either side of the jamb, fit the weatherstrip up tight against the temporarily attached
weatherstrip in the header and 1/8” to 1/4” inside the jamb edge. Temporarily secure the
weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom sec­tion from falling out of the opening during installation. Equally space nails approximately 12”
to 18” apart.

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” low headroom 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.

*NOTE: For door heights from 10’1” to 14’0”, refer to your operator manufacture installation
instructions for appropriate depth into room.

BACKROOM REQUIREMENTS

Door Height Track Manual Lift Motor Operated

6’0” to 7’0” 12”, 15” Radius 106” (2692 mm) 125” (3175 mm)

7’1” to 8’0” 12”, 15” Radius 118” (2997 mm) 137” (3480 mm)

HEADROOM REQUIREMENTS

Track Type Space Needed

3” LHR 3-1/2” (89 mm)

6” LHR 6” (152 mm)

Min. Side

Suitable mounting surface

2”x 6” lumber minimum

Header board 2”x 6”

lumber preferred

Headroom

room

Clearance

is 3 1/2”

Backroom

Quick install jamb

Track rollers

(as required)

Strut (U-bar)

(if included)

Fully Adjustable jamb

brackets (as required)

Drawbar

operator bracket

(2) 5/16”-18 x

)

Fully Adjustable flag angles RH/LH (as required)

Riveted vertical track assemblies RH/LH (as required)

Vertical tracks RH/LH (as required)

Horizontal tracks RH/LH

Pull down

rope (if included)

(2) Top fixtures

Weatherstrips & nails

(If included)

Strut (A-symmetrical)

(if included)

Spring restraint cables

Min. Side
room
Clearance
is 3 1/2”

Weatherstrips

Plumb
jambs

Level header

Finished

Finished

Door width

Door

Height

Nail

Jamb

Jambs

Quick Install track

Jamb

Other track systems

Weatherstrips

1/8” to 1/4”

Package Contents

NOTE: Depending on the door model, some parts listed will not be supplied if not required.
Rear Back Hangs may not be included with your door.

Door sections (as required)

(2) Front

(2) Hook plates

(as required)

1/4”- 20 Flanged

1/4”-20 x 9/16”

(2) Rear

5/16” x 1-5/8” Hex head lag screws

3 Hole clips

(as required)

(2) 5/16”-18 Hex nuts (2) 3/8”- 16 Hex nuts

1/4”-14 x 5/8” Self tapping

screws (as required)

(as required)

S-hooks

(as required)

drilling screws (as required)

(2) Sheave forks

5/16”-18 x 3/4”

1/4”-20 x 11/16” Self

(2) #12 x 1/2”

Phillips head screws

3/8” - 16 x 1-1/4”

Hex head bolts (as required)

Hex nuts (as required)

3/8”- 16

Cotter pin5/16” x 1-1/4” Clevis pin

3

Door Section Identification

Phillips head screwdrive

1/2”, 9/16”, 5/8”

Graduated end and center hinges are always pre-attached at the top of each section (except
top section) and the graduated end hinges are stamped for identification, #1, #2, #3, and #4
(#4 only on five section doors). 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. If the stamp on the graduated end hinge is illegible, refer to
the section side view illustration. The section side view illustration shows the graduated end
hinge profile of all sections, and can also be used to identify each section.

The BOTTOM SECTION can be identified by #1 graduated end hinges, the factory attached
bottom astragal, the factory attached bottom corner brackets, and by the bottom corner
bracket warning labels on each end stile.

The LOCK SECTION can be identified by #2 graduated end hinges.
The INTERMEDIATE SECTION can be identified by #3 graduated end hinges. The section

will have a warning label attached to either the right or left hand end stile.
NOTE: #4 graduated end hinges are used on the fourth section of five section doors.
The TOP SECTION can be identified with no pre-installed graduated end or center hinges.

1-9/16”

Warning label

Top section

#3

Warning label

Intermediate section

#2

1-3/8”

#3 Graduated

end hinge

1-1/8”

#4
Graduated
end hinge

Vise clamps Hammer Step ladder PencilLeather gloves

Saw horses

Approved winding bars

Locking pliersSafety glasses

Lock section

#1

Bottom corner bracket warning labels

Bottom weather seal

Typical

graduated end

hinge stamping

location

Bottom section

Section side view illustration

Tools Required

Drill bits: 1/8”, 3/16”,

Power drill Socket driver: 7/16” Level

Ratchet wrench Tape measure Pliers / Wire cutters Flat tip screwdriver

9/32”, 7/16”, 1/2”

#2 Graduated

end hinge

7/8”

Graduated
end hinge

Bottom corner

bracket

Bottom

weather seal

#1

Wrenches: 3/8”, 7/16”,

r

3” Ratchet

extension

Sockets: 7/16”,

1/2”, 9/16”, 5/8”

4

A2.

Lower hole

BREAKDOWN OF PARTS

NOTE: The illustrations shown on this page are general
representations of the door parts. Each specific door
models may have unique variations.

J5.

C1.

A1.

A2.

J3.

J6.

J5.

J4.

J7.

J10.

J1.

K2.

B1.

B2.

K1.

F1.

G2.

G1.

B1.

I6.

B2.

I4.

L2.

I1.

J9.

J2.

3rd
hole
set

2nd
hole set

1st hole
set

A1.

J5.

C1.

F1.

J2.

J3.

J6.

J5.

J4.

J9.

D1.

I3.

I5.

C1.

L1.

D2.

C2.

J7.

J10.

J1.

H1.

E4.

E1.

E2.

E3.

J8.

J5.

I2.

Top of

vertical

track

B1. (Quick

Install

Feature)

Top

hole

Middle

hole

Bottom

hole

J8.

Top of

vertical

track

3rd
hole
set

2nd
hole set

1st
hole set

J5.

B2. (Fully

Adjustable

Feature)

of hole/
slot pattern

A. FLAG ANGLES (AS REQUIRED):

A1. Quick Install (Q.I.) Flag Angles
A2. Fully Adjustable (F.A.) Flag Angles

B. JAMB BRACKETS (AS REQUIRED):

B1. Quick Install (Q.I.) Jamb Brackets
B2. Fully Adjustable (F.A.) Jamb Brackets

C. TRACK ROLLERS (AS REQUIRED):

C1. Short Stem Track Rollers
C2. Long Stem Track Rollers

D. GRADUATED END HINGES:

D1. Single Graduated End Hinges (S.E.H.), Anti-Pinch
D2. Double Graduated End Hinges (D.E.H.), Anti-Pinch

E. STACKED SECTIONS:

E1. Top Section
E2. Intermediate(s) Section
E3. Lock Section
E4. Bottom Section

F. TOP FIXTURE ASSEMBLIES (AS REQUIRED):

F1. Top Fixture Assemblies

G. STRUT(S) (AS REQUIRED):

G1. Strut (U - shaped)
G2. Strut (asymmetrical)

H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):

H1. Drawbar Operator Bracket

TRACKS (AS REQUIRED):

I1. Left Hand Horizontal Track Assembly
I2. Right Hand Horizontal Track Assembly
I3. Left Hand Vertical Track
I4. Right Hand Vertical Track
I5. Left Hand Riveted Vertical Track Assembly
I6. Right Hand Riveted Vertical Track Assembly

J. LOW HEADROOM EXTENSION SPRING ASSEMBLY:

J1. Extension Springs
J2. Spring Restraint Cables
J3. Front Cable Lift Sheaves
J4. Rear Cable Lift Sheaves
J5. 3 Hole Clips (As Required)
J6. S-Hooks (As Required)
J7. Sheave Forks (As Required)
J8. 5/16” - 18 x 3-3/4” Eye Bolts (As Required)
J9. Counterbalance Lift Cables
J10. Hook Plates (As Required)

K. REAR BACK HANGS (AS REQUIRED):

K1. Left Hand Rear Back Hang Assembly
K2. Right Hand Rear Back Hang Assembly

L. BOTTOM CORNER BRACKETS (AS REQUIRED):

L1. Left Hand Bottom Corner Bracket
L2. Right Hand Bottom Corner Bracket

5

INSTALLATION

Bottom weather seal

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.

NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.
IMPORTANT: IF THE DOOR WILL BE EXPOSED TO A SIGNIFICANT AMOUNT OF ROAD SALT,

PAINT THE BARE GALVANIZED BOTTOM WEATHER STEEL RETAINER TO INHIBIT RUSTING.

Attaching Flag Angles and Jamb Brackets To

1

NOTE: If you have Riveted Track or Angle Mount Track, skip this step.
FOR DOORS WITH QUICK INSTALL TRACK: Place the lower Quick Install tab of the left

hand flag angle in the Quick Install feature of the left hand vertical track. Give the flag angle
1/4 turn to lock in place. 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 Quick Install tab on the Quick Install jamb
bracket with the Quick Install 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 the same
process for right hand side.

DOOR

HEIGHT

6’0” 57-3/4” 5 M 8 T N/A

6’5” 62-3/4” 3 B 7 M N/A

6’8”

- 7’0”

7’3”

- 8’0”

Vertical Tracks

Jamb Bracket Schedule

VERTICAL

TRACK

LENGTH

66” - 69-

1/2”

72-1/2” -

88”

1ST SET 2ND SET 3RD SET

JAMB

POSITION JAMB

BKT

3 B 6 M N/A

3 B 7 T 8 T

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

BKT

POSITION JAMB

BKT

POSITION

3rd

Left hand
flag angle

NOTE: Loosely fasten
components together.

Repeat the same process

for the right hand side.

Set

Left hand

jamb bracket

2nd

Set

Left hand

vertical track

Left hand

jamb bracket

1st
Set

Cable Drum Assemblies and Track Rollers

2

NOTE: Refer to door section identification, located in the pre-installation section of this
manual or refer to Breakdown of Parts.

WARNING

FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER CLEVIS PIN
COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN,
ALLOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR
FATAL INJURY.

Uncoil the counterbalance lift cables. Locate the left hand bottom corner bracket. Place clevis
pin into the inside tab of the bottom corner bracket and slide the cable loop of the counter­balance lift cable onto pin. Continue sliding clevis pin thru the outside tab of the bracket.
Place a washer onto clevis pin and secure in place using a cotter pin.

Counterbalance

lift cable

Counterbalance

lift cable

1/4

Turn

Top

Middle

hole

hole

Left hand

jamb bracket

Bottom

hole

1st
Set

Left hand

vertical

track

Left hand
flag angle

NOTE: Repeat the

same process for

the right hand side.

1/4

Turn

3rd
Set

Left hand

jamb bracket

2nd Set

FOR DOORS WITH FULLY ADJUSTABLE TRACK: 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.

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. Hand tighten jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” – 20
flange hex nut.

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. Hand tighten jamb
bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 flange hex nut.

If a top jamb bracket was included, hand tighten 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.

Bottom corner

bracket warning label

Milford pin Milford pin

Cable loop

Left hand

bottom corner

brackets

Bottom section

Right hand

bottom corner

brackets

Bottom corner

bracket warning label

Cable loop

Inside

tab

Outside tab

Counterbalance

lift cable

Washer

Cotter

pin

Clevis

pin

Position the left hand bottom corner bracket onto the bottom section. Attach the bottom
corner bracket to the bottom section with (3) 1/4” - 20 x 11/16” RED HEAD self drilling
screws and (2) 1/4” - 20 x 11/16” self drilling screws, as shown. Repeat same process for
the right hand side.

IMPORTANT: THE 1/4” - 20 X 11/16” RED HEAD SELF DRILLING SCREWS MUST BE MUST
BE INSTALLED THROUGH THE HOLES OF THE BOTTOM CORNER BRACKETS, AS SHOWN.

Insert a short stem track roller into the bottom corner brackets and another into the #1
graduated end hinges at the top of the bottom section.

NOTE: Larger doors will use long stem track rollers with double graduated end hinges.
NOTE: Verify bottom weather seal is aligned with bottom section. If there is more than 1/2”

excess weather seal on either side, trim weather seal even with bottom section.

6

#1 Single

1/4” - 14 x 5/8”

graduated
end hinge

(Hinge tube)

Short stem
track roller

Counterbalance

lift cable

Bottom corner

bracket

Short stem
track roller

3

Bottom section

Bottom corner

bracket

warning label

1/4”-20 x 11/16”

Self drilling screws

1/4” - 20 x 11/16” Self

drilling screws (RED HEAD)

Positioning Bottom Section

Double
graduated
end hinge

(Hinge tube)

Counterbalance

lift cable

Long stem
track roller

Bottom
section

Bottom

weather seal

Flag

angle

Vertical

track

assembly

Jamb

bracket

Bottom
section

5

5/16” x 1-5/8”

Lag screws

Track
rollers

12R FA

Floor

15R FA

Flag angle lag screw locations

3/8” to 5/8”

Spacing

Bottom section

Vertical track

Attaching Top Fixtures To Top Section

15R QI12R QI

Track roller

Center the bottom section in the door opening. Level the section using wooden shims (if
necessary) under the bottom section. When the bottom section is leveled, temporarily hold it
in place by driving a nail into the jamb and bending it over the edge of the bottom section on
both sides.

Weather seal (If applicable)

Level

Bottom section

Wooden shims (If necessary)

Vertical Tracks

4

NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable
Flag Angles or you may have Riveted Vertical Track Assemblies. Refer to Package Contents /
Breakdown of Parts, to determine which Flag Angles / Vertical Track Assemblies you have.

IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION
OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION
ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO
DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.

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.

Starting on the left hand side of the bottom section, remove the nail. Position the left hand
vertical track assembly over the track rollers of the bottom section. Make sure the counter­balance lift cable is located between the track rollers and the door jamb.

NOTE: Drill 3/16” pilot holes into 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, between the bottom section and vertical track. Hang counterbalance lift cable over flag
angle. Repeat same process for other side.

NOTE: Depending on your door, you may have strut (U-shaped) or asymmetrical strut. Refer
to Package Contents / Breakdown of Parts, to determine which type of strut you have.

NOTE: The top fixtures come pre-assembled from the factory.
Place the strut (U-shaped) or the asymmetrical strut over the top rib of the top section, as

shown.

Top fixture

assembly

Strut

(asymmetrical)

Male

part of

top

section

Top rib

Top section

Strut (U-shape)

(attached to top rib)

(attached to top rib)

Long leg

Short

leg

Center the strut left to right on the section surface. Starting on the left hand side, locate the
edge of the top section and seat the top fixture on the male part of the top section, as shown.
Secure the top fixture assembly and the strut to the top section:

1. Attach one 1/4” - 14 x 5/8” self-tapping screw to the top fixture assembly.

2. Attach two 1/4” - 20 x 11/16” self-drilling screws to the top fixture assembly.

3. Attach two #12 x 1/2” phillips head screws on the opposite side of top fixture assembly.
Insert a roller into the top fixture slide, as shown. Repeat the same process for the other side.

NOTE: The top fixture slide will be tightened and adjusted later, in step, Adjusting Top Fixture.
NOTE: Ensure the top fixture slide is able to slide along the top fixture base. If needed, loosen

the 1/4” - 20 flange hex nuts.
IMPORTANT: IF YOU’RE SECURING AN ASYMMETRICAL STRUT TO THE TOP SECTION, IT IS

RECOMMENDED NOT TO INSTALL ANY FASTENERS INTO THE SHORT LEG OF THE ASYM­METRICAL STRUT.

Self tapping screw

#12 x 1/2” Phillip

Short stem
track roller

1/4” - 20 x 11/16”
Self drilling screws

pan head screws

Strut

Top

fixture

slide

Top section

IF YOU HAVE A STRUT (U-SHAPED): Fasten each end of the strut to the end cap with (2)

7

1/4” - 20 x 11/16” self drilling screws. Fasten center of the strut as shown to the rib using

=

Drawbar operator

Backside of

(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.

Strut

Strut

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

NOTE: When attaching drawbar operator bracket to top section with strut, apply additional
pressure to thread into the strut.

drawbar operator

bracket

1/4”- 14 x 5/8”

Self-tapping screws

Top section

(2) 1/4”-14 x 5/8”

Self tapping screws

30” To 36”

6”

=

Center line of top section

IF YOU HAVE AN ASYMMETRICAL: Fasten each end of the asymmetrical strut to the end
cap with (2) 1/4” - 20 x 11/16” self drilling screws. Fasten center of the asymmetrical strut
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 wall and the long leg of
the asymmetrical strut, as shown using (2) 1/4” - 14 x 5/8” self tapping screws every 30 ­36 inches. (Approximately 18 self tapping screws per 18’ asymmetrical strut)

Asymmetrical

strut

Top section

(2) 1/4”-14 x 5/8”

Self tapping screws

30” To 36”

6”

Top section

(2) 1/4”-14 x 5/8”

Self tapping screws

6”

(2) 1/4”-14 x 5/8”

Self tapping screws

6”

=

Asymmetrical

Top section

End cap

strut

End cap

= =

Center line of top section

bracket

(2) #12 x 1/2”

Phillips head screws

NOTE: Clamp drawbar operator bracket to

strut (if supplied) with vise clamps.

Stacking Sections

7

NOTE: The sections can be identified by the graduation of the factory installed graduated end
hinges. The smallest graduated end hinge on section should be stacked on top of the bottom
section, with each graduated end hinge increasing as the sections are stacked, see Door
Section Identification / Breakdown of Parts.

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

NOTE: Larger doors will use long stem track rollers with double graduated end hinges.
Place track rollers into graduated end hinges of remaining sections.
With assistance, lift second section and guide the track rollers into the vertical tracks. Lower

section until it is seated against bottom section. Flip hinges up. Fasten center hinge(s) first;
then end hinges last using 1/4” - 14 x 5/8” self tapping screws.

NOTE: To prevent center hinge leaf(s) from rotating, first secure the top middle hole of the
center hinge leaf with one 1/4” - 14 x 5/8” self-tapping screw then secure the other two
holes.

NOTE: Larger doors with double graduated end hinges, fasten both hinges to connect the
sections using 1/4” - 14 x 5/8” self-tapping screws.

Repeat same process for other sections, except top section.
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.

NOTE: Install lock at this time (sold separately). See optional installation step, Side Lock.

Attaching Drawbar Operator Bracket

6

NOTE: If you’re installing a drawbar operator, the drawbar operator bracket must be mounted
and secured prior to installing top section.

IMPORTANT: TO AVOID POSSIBLE DAMAGE TO YOUR DOOR, WAYNE DALTON RECOM­MENDS REINFORCING THE TOP SECTION WITH A STRUT.

IMPORTANT: WHEN CONNECTING A DRAWBAR OPERATOR TYPE GARAGE DOOR OPENER
TO THIS DOOR, A WAYNE DALTON OPERATOR/ DRAWBAR OPERATOR BRACKET MUST
BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY STRUT
PROVIDED WITH THE DOOR. THE INSTALLATION OF THE DRAWBAR OPERATOR MUST BE AC­CORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED
PROPERLY.

Prior to installing the top section, locate the center of the top section and seat the drawbar
operator bracket on top of the top section. For retro fit applications, the drawbar operator
bracket must be aligned with an existing drawbar operator and positioned on top section so it
bridges the transition point of the section thickness.

Top section

Drawbar operator

bracket label

Install (2) #12 x 1/2” phillips head screws on the back side of drawbar operator bracket.
Clamp drawbar operator bracket to strut (if supplied) with vice clamps. Attach (6) 1/4” - 14 x
5/8” self-tapping screws to the drawbar operator bracket. Remove vice clamps.

Center line of

top section

Vertical

track

Intermediate

section

Lock

section

Bottom
section

Vertical

track

8

Left graduated end hinge

1/4”-14 x 5/8” Self tapping screw locations

Level

track

NOTE: Repeat the same

with short stem track roller

1/4”-14 x 5/8” Self tapping screw locations

Center

hinge(s)

Right graduated end hinge
with short stem track roller

Upper rail

Flag angle
upper slot

Lower

rail

Key
slot

Quick
Install

tab

Level

Quick
Install
tab in
place

1/4”-20

Flange hex

nut

Washer

Flag

angle

1/4”-20 x

9/16”

Track bolt

Left double graduated

end hinge with long

stem track roller

Center

hinge(s)

Right double graduated

end hinge with long

stem track roller

Stacking Top Section

8

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 or wall
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 or wall angles must be parallel to the door sections. Repeat for
other side.

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

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

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

Door width

+ 3-3/8” to 3-1/2”

Top of flag

angle

Nail

Top section

1-11/16”
to 1-3/4”

Horizontal

track

IF YOU HAVE FULLY ADJUSTABLE FLAG ANGLES OR RIVETED TRACK ASSEMBLIES:
To install horizontal track, place the top rail end over the top track roller of the top section.
Align the bottom rail end of the horizontal track with the top of the vertical track. Tighten the
bottom rail of the horizontal track to the flag angle with (2) 1/4” - 20 x 9/16” track bolts and
(2) 1/4” - 20 flange hex nuts.

Upper rail

1/4”-20

Flange hex

nuts

Flag angle
upper slot

Next level the horizontal track assembly and bolt the top rail of the horizontal track to the
encountered slot in the flag angle using (1) 1/4” - 20 x 9/16” track bolt, (1) 1/4” - 20 flange
hex nut and (1) 5/16” washer. Repeat for other side.

Typical horizontal

track

Lower

rail

Level

Horizontal

track

Level

1/4”-20 x

9/16”

Track bolts

1/4”-20

Flange hex

nut

Washer

1/4”-20 x

9/16”

Track bolt

Flag

angle

Top

section

Flag angle

assembly

Vertical track
against track rollers

Attaching Horizontal Tracks

9

NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable
Flag Angles or you may have Riveted Vertical Track Assemblies. Refer to Package Contents /
Breakdown of Parts, to determine which Flag Angles / Vertical Track Assemblies you have.

WARNING

DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT
REAR, AS OUTLINED IN STEP, REAR BACK HANGS, OR DOOR COULD FALL
FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY.

IF YOU HAVE QUICK INSTALL FLAG ANGLES: To install horizontal track, place the curved

end over the top track roller of the top section. Align key slot of the horizontal track with the
Quick Install tab of the flag angle. Push curved portion of horizontal track down to lock in
place. Level the horizontal track assembly and bolt the top rail of the horizontal track to the
encountered slot in the flag angle using (1) 1/4” - 20 x 9/16” track bolt, (1) 1/4” - 20 flange
hex nut and (1) 5/16” washer. Repeat for other side.

Typical horizontal

Next remove the nail that was temporarily holding the top section in place, installed in step,
Top Section.

IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD
CAUSE PERMANENT DAMAGE TO TOP SECTION.

Adjusting Top Fixtures

10

With horizontal tracks installed, you can now adjust the top fixtures. Vertically align the top
section of the door with the lower sections. Once aligned, position the top fixture slide, out
against the horizontal track. Maintaining the slide’s position, tighten the (2) 1/4” - 20 flange
hex nuts to secure the top fixture slide to the top fixture base. Repeat for other side.

process for the other side.

Tighten the (2) 1/4”- 20

Flange hex nuts

Top

section

Track
roller

Top fixture

slide

Horizontal

track

Top

section

Int.

section

COUNTERBALANCE

INSTALLATION INSTRUCTIONS

9

Attaching Cable Lift Sheaves

11

Place a 3/8” - 16 x 1-1/2” truss head bolt through the sheave plate hole in the horizontal
track and slide the sheave over the end of the bolt, as shown. Secure the sheave using (1)
3/8” - 16 hex nut.

Repeat for the other side and loop the counterbalance lift cables over each sheave.

Front cable lift sheave

Horizontal track

Flag

angle

3/8”-16

Hex nut

3/8” - 16 x 1-1/2”

Truss head bolt

Sheave

hole

location

process for the right hand side.

Counterbalance

lift cable

Front cable

lift sheave

NOTE: Repeat the same

Attaching Rear Back Hangs

12

Perforated

angle

90°

(3) 5/16” Bolts and

(3) 5/16” nuts

Perforated angle bolted

using (2) 5/16” x 1-5/8”

hex head lag screws to

ceiling member and

parallel to door

(3) 5/16”

Bolts and nuts

Raise the door until the top section and half of the next section are in the horizontal track
radius. Do not raise door any further since rear of horizontal tracks are not yet supported.

WARNING

RAISING DOOR INTO THE LOOSE HORIZONTAL TRACKS CAN RESULT IN
DOOR FALLING AND CAUSE SEVERE OR FATAL INJURY.

Clamp a pair of locking pliers onto the vertical tracks just above the second track roller on
one side, and just below the second track roller on the other side. This will prevent the door
from raising or lowering while installing the rear back hangs.

Using the chart below, select the appropriate perforated angle (may not be supplied). Fabri­cate and install rear back hangs, as shown.

Perforated Angle Gauge Weight Limitations:

Perforated Angle Gauge Door Balance Weight

2” x 2” x 12 Gauge Less Than 800 lbs.

1-1/4” x 1-1/4” x 13 Gauge Less Than 305 lbs.

1-1/4” x 1-1/4” x 15 Gauge Less Than 220 lbs.

1-1/4” x 1-1/4” x 16 Gauge Less Than 175 lbs.

NOTE: If an opener is installed, position horizontal tracks one hole above level when securing
them to the rear back hangs.

WARNING

KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4” TO 7/8” FROM
DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN SEVERE OR
FATAL INJURY.

IMPORTANT: DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR

BACK HANGS THAT CANTILEVERS 4” OR MORE BEYOND A SOUND FRAMING MEMBER.
NOTE: If rear back hangs are to be installed over drywall, use (2) 5/16” x 2” hex head lag

screws and make sure lag screws engage into solid structural lumber.

WARNING

FAILURE TO ASSEMBLE AND ATTACH REAR BACK HANGS PROPERLY
ACCORDING TO THE ABOVE INSTRUCTIONS MAY RESULT IN DOOR
FALLING WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.

NOTE: Perforated angle must be attached to sound framing members and nails should not
be used.

Horizontal track

5/16”-18 x 1-1/4”

Hex bolts

3/4” To 7/8”

Door edges

Horizontal tracks

5/16” Hex nuts

3/4” To 7/8”

NOTE: Repeat the same

process for right hand side.

Attaching Extension Springs

13

WARNING

WITH ASSISTANCE, RAISE THE DOOR SLOWLY INTO THE OPEN POSITION
MAKING SURE THE DOOR TRAVELS SMOOTHLY THROUGH THE TRACKS.
CLAMP LOCKING PLIERS TO THE BACK LEG OF BOTH HORIZONTAL
TRACKS, BELOW THE BOTTOM TRACK ROLLERS TO KEEP THE DOOR
FROM LOWERING.

WARNING

FAILURE TO INSTALL SPRING RESTRAINT CABLES CAN RESULT IN
SEVERE OR FATAL INJURY IN CASE OF SPRING BREAKAGE.

Position the 5/16” - 18 x 3-3/4” eye bolt and (2) 5/16” - 18 hex nuts into the extension
spring bracket. Feed the spring restraint cable through the extension spring and the rear
back hang. Tie the special knot around the “room side” of the 3 hole clip, as shown. Secure
the 3 hole clip to the rear back hang using a 5/16” - 18 x 1” hex bolt and a 5/16” - 18 hex
nut.

With the spring restraint cable going through the extension spring, pull the spring restraint
cable taut and tie the special knot around the “jamb side” of the 3 hole clip. Attach the “jamb
side” 3 hole clip to the jamb near the flag angle using (1) 5/16” x 1-5/8” lag bolt. Repeat the
same process for the other side.

10

IMPORTANT: SPRING RESTRAINT CABLES MUST BE TAUT AND EQUALIZED.

NOTE: This illustration shows the outside of the door

Spring

in the open position.

Track
roller

Locking

Bottom
section

5/16” x 1-5/8”

3 Hole

clip

Spring

restraint

cable

Loop

Extension

5/16”-18 x 3-3/4”

Eye bolt

Horizontal track

5/16”-18 x 3-3/4”

Eye bolt

5/16”-18

Hex nut

Extension spring bracket

NOTE: As an option, eyebolt may be fastened to rear back hangs and extension spring bracket
left unused. The extension spring bracket is useful in applications where rear headroom is
small, resulting in short rear back hangs.

5/16”-18 Hex nut

spring

Extension

spring

Extension

spring

5/16”-18 x 3-3/4”

Spring

restraint

cable

pliers

Lag bolt

Front view

Horizontal

track

Spring restraint

cable

Eye bolt

Rear
back
hang

Back
view

Spring safety

cable

Extension

spring

5/16” - 18 x 1”

Hex bolt

Spring

restraint

cable

Special

knot

3 Hole

clip

Special

knot

Rear
back
hang

5/16”-18

Hex nut

Rear
back

hang

3

Hole

clip

NOTE: Some larger doors feature 2 pairs of extension springs. A spring restraint cable must
be installed through each spring.

Counterbalance

lift cable

Rear

cable lift

sheave

Hook plate

SPRINGS FROM COMING LOOSE.

WARNING

FAILURE TO CLOSE “S” HOOKS AND EYE BOLTS CAN RESULT IN SEVER
OR FATAL INJURY IF SPRINGS COME LOOSE.

restraint

cable

Counterbalance Lift Cable Adjustments

15

Adjust counterbalance lift cables to create about 1” to 2” (25 mm to 50 mm) of pre-stretch
on the extension spring, with the door in the fully opened position. Measure extension spring
length (door open) and verify with the chart below. Spring length must be the same for both
left hand and right hand extension springs to allow even door balance. Carefully remove the
locking pliers from the horizontal track and lower the door into the closed position. Once the
door is closed, measure the extension spring length for both sides. Using the chart, verify the
spring length extended is correct for your door height.

Door Height Spring Length (Door Open)

6’ 0” 25” (635 mm) 61” (1549 mm)

6’ 3” 25” (635 mm) 62-1/2” (1588 mm)

6’ 6” 25” (635 mm) 64” (1626 mm)

7’ 0” 25” (635 mm) 67” (1702 mm)

7’ 6” 27” (686 mm) 72” (1829 mm)

7’ 9” 27” (686 mm) 73-1/2” (1867 mm)

8’ 0” 27” (686 mm) 75” (1905 mm)

Balancing Door

16

“S”

Hook

Counterbalance

“S”

Hook

3/8” - 16

Hex nut

Sheave fork

3 Hole clip

Special

knot

lift cable

Rear cable lift sheave

Extension spring

(Does Not Include Pre-

Rear cable
lift sheave

Extension spring

3/8”-16 x 1-1/4”

Hex head bolt

stretch)

Sheave fork

Extension

spring

Horizontal

track

Rear back hang

Spring Length Extended

(Door Closed)

(Does Not Include Pre-

stretch)

Spring restraint

cable

Counterbalance

lift cable

This illustration shows doors featuring (2) pairs of extension springs

Sheave fork

Attaching Spring Sheaves

14

Hook the sheave fork through the front loop of the extension spring. Attach the sheave fork
to the rear cable lift sheave using (1) 3/8” - 16 x 1-1/4” hex head bolt and (1) 3/8” - 16 hex
nut. Thread the counterbalance lift cable over the front cable lift sheave and around the rear
cable lift sheave. On one end of the 3 hole clip, tie the special knot. On the opposite side of
the 3 hole clip hook a large “S” hook into it. Secure the opposite end of the large “S” hook
into the horizontal track, as shown. Repeat the same process for the other side.

IMPORTANT: CLOSE “S” HOOKS AND EYE BOLTS WITH LOCKING PLIERS, TO PREVENT

Horizontal track

If door raises more than 2 ft. under spring tension alone, reduce spring tension. Adjust
extension spring length by loosening the special knot on the 3 hole clip and lengthen the
counterbalance lift cable between the 3 hole clip and the extension spring about 1/2”. If door
is hard to raise or drifts down on its own, add spring tension. Adjust extension spring length
by loosening the special knot on the 3 hole clip and shortening the counterbalance lift cable
between the 3 hole clip and the extension spring about 1/2”. A poorly balanced door can
cause garage door operator problems.

IMPORTANT: WHENEVER ADJUSTING EXTENSION SPRING LENGTH FOR DOOR BALANCE,
ALWAYS OPEN THE DOOR TO THE FULLY OPEN POSITION AND RETURN THE LOCKING
PLIERS, AS SHOWN IN F3 TO THE HORIZONTAL TRACKS BELOW THE BOTTOM TRACK
ROLLERS.

If the door still does not operate easily, raise the door into the open position, return the lock­ing pliers, and recheck the following items:

1.) Is the door level?

2.) Are the flag angles level and plumb?

3.) Does the distance between the flag angles equal door width plus 3-3/8” to 3-1/2”?

4.) Do the counterbalance lift cables have equal tension? Adjust by re-tieing the special knot,
if necessary.

5.) Make sure door is not rubbing on jambs.
IMPORTANT: IF DOOR STILL DOES NOT BALANCE PROPERLY, THEN CONTACT A TRAINED

DOOR SYSTEM TECHNICIAN.

11

Attaching Weather Seal

seal

installed

17

Permanently attach the weatherstrips on both door jambs and header. The weatherstrips
were temporarily attached in Preparing the Opening, in the pre-installation section of this
manual.

NOTE: When permanently attaching the weatherstrips to the jambs, avoid pushing the weath­erstrips too tightly against the face of door.

NOTE: Door not shown for clarity.

Header

Jamb

Weather seals

Jamb

Weather

Nail

Jamb

Nail

Weather seal

12

Optional Installation

Door Arm Hookup

Align hole in the door arm with holes in drawbar operator bracket tabs, as shown. Insert
5/16” x 1-1/4” clevis pin, making sure hole in clevis pin is outside of second tab of drawbar
operator bracket. Insert hairpin cotter into clevis pin hole and spread hairpin cotter to secure
assembly, as shown.

Drawbar operator bracket

Drawbar operator bracket tabs

5/16”x 1-1/4”
Clevis pin

Cotter pin

Door arm

Clevis pin

Spread cotter pin

Trolley Arm Configuration

Measure the horizontal radius of the horizontal track to determine if you have a 12” or 15”
radius horizontal track, as shown in FIG. 1; if you have a low headroom door skip this step.
Determine center line of the door. Mark vertical line at this point on the header, as shown in
FIG. 4. Raise the door slightly until the top section reaches the highest point of travel (high
arc), as shown in FIG. 2 and FIG. 3 for low headroom. Using a level, mark this high arc point
onto the header where it intersects the vertical center line, as shown in FIG. 4. Hold the wall
bracket’s bottom edge 1/2” - 1” (room permitting) above the high arc line and centered on
the vertical center line, as shown in FIG. 4. Mark the wall bracket’s 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.

NOTE: Refer to your operator manual for specific details on how to assembly the curved and
straight arm.

Align hole in the appropriate arm with holes in drawbar operator bracket tabs, as shown in
step, Trolley Arm Hookup. Insert 5/16” x 1-1/4” clevis pin, making sure hole in clevis pin is
outside of second tab of drawbar operator bracket. Insert cotter pin into clevis pin hole and
spread hairpin cotter to ensure it will secure assembly.

NOTE: Depending on your door, configuration, you could have an alternative drawbar opera­tor brackets. Refer to your alternative drawbar operator bracket insert.

WARNING

PRIOR TO INSTALLING THE OPERATOR TROLLEY ARM TO THE DOOR,
UNPLUG THE GARAGE DOOR OPERATOR. WITH THE DOOR IN THE FULLY
CLOSED POSITION, PLACE LOCKING PLIERS ONTO BOTH VERTICAL
TRACKS JUST ABOVE THE THIRD TRACK ROLLER. THIS IS TO PREVENT
THE GARAGE DOOR FROM RISING UNEXPECTEDLY WHILE INSTALLING
THE OPERATOR TROLLEY ARM TO THE DOOR. AFTER INSTALLING THE
OPERATOR TROLLEY ARM TO THE DOOR REMOVE THE LOCKING PLIERS
AND PLUG THE GARAGE DOOR OPERATOR BACK INTO THE OUTLET.

Level

High arc

Horizontal

Horizontal

radius

track

Top section

Level

High arc

Low headroom track

Top section

Typical 1/2”-1”

above high arc

High arc line

Header

From step

FIG 4FIG 3

TorqueMaster
counterbalance

Vertical

center line

®

Inside Lock

Install the inside 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 inside lock should be spaced ap­proximately 1/8” away from the section edge.

IMPORTANT: INSIDE LOCK(S) MUST BE REMOVED OR MADE INOPERATIVE IN THE UN­LOCKED POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR.

Square hole in

Lock

(Second)

section

Inside lock

End cap

vertical track

1/4”-20 x 11/16”

Self drilling screws

1/8”

Pull Down Rope

WARNING

DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH 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 jamb. Drill 1/8” pilot hole for no. 6 screw eye. Tie the pull down rope to the
no. 6 screw eye and to the bottom corner bracket, as shown.

No. 6 Screw eye

Pull rope

12” or 15”

FIG 1

FIG 2

13

48” to 50”
From floor

Pull rope

Step Plate

Bottom bracket

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.

NOTE: Top of step plate can be no higher than 8” from the bottom of the door.
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 models 9405/9605
Tighten 1/4” - 20 carriage bolt and nut.

Step plate
slide

Step plate

base

Hex nut

Bottom
Section

Strut

Assembled inside step plate

#8 screw

2-3/16”

1”

Outside step plate

Bottom
section

1/4” - 20 x 5/8”
Carriage bolt

14

Maintenance

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 weatherstrips on both sides and top of door.

CAUTION

NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

NOTE: Do not use any window cleaning fluids, scouring compounds, gritty cloths or solvent­based cleaners of any kind.

To clean polycarbonate windows, see www.Wayne-Dalton.com.

Painting Your Garage Door

Refer to Instruction Insert “Field Painting and Finishing Fiberglass or Steel Door Sec­tions”.

Maintaining The Finish

On Your Garage Door

If the factory finish is beginning to fade, the door may require a field applied top clear coat.
Depending on environment and usage, this may be necessary after 1 to 3 years of use. Refer
to Instruction Insert “Field Painting and Finishing Fiberglass Or Steel Door Sections”.

Operation And Maintenance

OPERATING YOUR GARAGE DOOR: Before you begin, read all warning labels affixed to
the door and the installation instructions and owner’s manual. When correctly installed, your
Wayne Dalton door will operate smoothly. Always operate your door with controlled move­ments. Do not slam your door or throw your door into the open position, this may cause dam­age to the door or its components. If your door has an electric opener, refer to the owner’s
manual to disconnect the opener before performing manual door operation below.

MANUAL DOOR OPERATION: For additional information on manual garage door operations
go to www.dasma.com and reference TDS 165.

WARNING

DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN
OPENING AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES /
SUITABLE GRIPPING POINTS WHEN OPERATING THE DOOR MANUALLY.

OPENING A DOOR: Make sure the lock(s) are in the unlocked position. Lift the door by using

the lift handles / suitable gripping points only. Door should open with little resistance.
CLOSING A DOOR: From inside the garage, pull door downward using lift handles / gripping

point only. If you are unable to reach the lift handles/ suitable gripping points only, use pull
down rope affixed to the side of door. Door should close completely with little resistance.

USING AN ELECTRIC OPERATOR:
IMPORTANT: PULL DOWN ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR

MADE INOPERATIVE IN THE UNLOCKED POSITION.
When connecting a drawbar (trolley type) garage door operator to this door, a drawbar opera-

tor bracket must be securely attached to the top section of the door, along with any struts
provided with the door. Always use the drawbar operator bracket supplied with the door. To
avoid possible damage to your door, Wayne Dalton recommends reinforcing the top section
with a strut (may or may not be supplied). The installation of the drawbar operator must be
according to manufacturer’s instructions and force settings must be adjusted properly. Refer
to the owner’s manual supplied with your drawbar operator for complete details on installa­tion, operation, maintenance and testing of the operator.

MAINTAINING YOUR GARAGE DOOR: Before you begin, read all warning labels affixed to
the door and the installation instructions and owner’s manual. Perform routine maintenance
steps once a month, and have the door professionally inspected once a year. Review your

Installation Instructions and Owner’s Manual for the garage door. These instructions are
available at no charge from Wayne Dalton, a division of Overhead Door Corporation, P.O. Box
67, Mt. Hope, OH., 44660, or at www.Wayne-Dalton.com. For additional information on
garage door/operator maintenance go to www.dasma.com and reference TDS 151, 167
and 179.

Monthly Inspections:

1. Visual Inspection: Closely inspect jambs, header and mounting surface. Any material

found not to be structurally sound must be replaced. It may be necessary to uninstall part
or all of the door assembly in order to replace defective material. Refer to the supplemental
instructions “Removing an Existing Door / Preparing the Opening” at www.Wayne-Dalton.
com. Inspect the spring(s), counterbalance lift cables, track rollers, pulleys, rear back hangs
and other door hardware for signs of worn or broken parts. Tighten any loose screws and/or
bolts, except on bottom corner brackets or on the counterbalance assembly. Check exterior
surface of the door sections for any minor cracks. Verify door has not shifted right or left in
the opening. If you suspect problems, contact a trained door system technician.

WARNING

GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACKETS,
AND OTHER HARDWARE ATTACHED TO THE SPRINGS ARE UNDER
EXTREME TENSION, AND IF HANDLED IMPROPERLY, CAN CAUSE
SEVERE OR FATAL INJURY. ONLY A TRAINED DOOR SYSTEMS
TECHNICIAN SHOULD ADJUST THEM, BY CAREFULLY FOLLOWING THE
MANUFACTURER’S INSTRUCTIONS.

WARNING

NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR LAG
SCREWS ON THE COUNTERBALANCE (END BEARING BRACKETS, DRUMS
OR SPRING SYSTEM) OR BOTTOM CORNER BRACKETS OF THE DOOR.
THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER
EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY,
HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS
TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

TORQUEMASTER® PLUS SPRINGS: Pawl knob(s) (located on the TorqueMaster® end brack-

ets above the door) should be engaged to prevent the door from rapidly descending in case
of spring failure or forceful manual operation.

EXTENSION SPRINGS: A restraining cable or other device should be installed on the exten­sion spring (located above the horizontal tracks) to help contain the spring if it breaks.

2. Door Balance: Periodically test the balance of your door. If you have a garage door
drawbar operator, use the release mechanism so you can operate the door by hand when
doing this test. Start with the door in the fully closed position. Using handles or suitable grip­ping points, lift the door to check its balance. Adjust TorqueMaster® or Extension spring(s),
if door lifts by itself (hard to pull down) or if door is difficult to lift (easy to pull down). DO NOT
attempt to repair or adjust Torsion Springs yourself. To adjust TorqueMaster® or Extension
spring(s), refer to your installation instructions and owner’s manual. If in question about
any of the procedures, do not perform the work. Instead, have it adjusted by a trained door
systems technician.

3. Lubrication: The door should open and close smoothly. Ensure the door track rollers are
rotating freely when opening and closing the door. If track rollers do not rotate freely, clean
the door tracks, removing dirt and any foreign substances. Clean and lubricate (use a non­silicon based lubricant) graduated end hinges, center hinges, steel track rollers, bearings and
torsion springs (torsion spring coil surfaces). DO NOT lubricate plastic idler bearings, nylon
track rollers, door track. DO NOT oil a cylinder lock, if actuation is difficult use a graphite dust
to lubricate.

CHECK FOR PRESENCE OF SAFETY LABELS:

15

Bottom corner bracket warning labels

TorqueMaster

(one per spring)

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

Copyright 2010 Wayne Dalton, a

300547 REV2 01/15/2010

Division of Overhead Door Corp.

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.

Copyright 2010 Wayne Dalton, a Division of Overhead Door Corp.

323917 REV2 01/15/2010

Quality garage doors since 1954

Wayne Dalton

2501 S. State Hwy 121 Bus., Suite 200

Lewisville, TX 75067

For service, call [phone]

www.Wayne-Dalton.com

SAFETY INSTRUCTIONS

1. Operate door ONLY when it is properly

adjusted and free of obstructions.

2. 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.

3. DO NOT stand or walk under a moving door,
or permit anybody to stand or walk under
an electrically operated door.

4. DO NOT place fingers or hands into open
section joints when closing a door. Use lift
handles/gripping points when operating
door manually.

5. DO NOT permit children to operate garage
door or door controls.

6. 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
system technician using proper tools and
instructions.

7. On electrically operated doors, pull down
ropes must be removed and locks must be
removed or made inoperative in the open
(unlocked) position.

8. Top section of door may need to be
reinforced when attaching an electric
opener. Check door and/or opener
manufacturer’s instructions.

9. VISUALLY inspect door and hardware
monthly for worn and/or broken parts.
Check to ensure door operates freely.

10. Test electric opener’s safety features
monthly, following opener manufacturer’s
instructions.

11. NEVER hang tools, bicycles, hoses, clothing
or anything else from horizontal tracks.
Track systems are not intended or designed
to support such extra weight.

Place label at a readable height on door. DO NOT
remove, cover or paint over this label. Product
user should inspect this label periodically for
legibility and should order a replacement label
from the door manufacturer as needed.

Copyright 2013 Wayne Dalton, a

324100 REV7 09/16/2013

Division of Overhead Door Corp.

WARNING

The adjacent bottom corner
bracket and all cable
retention features including
milford pins, cotter pins, &
clevis pins are under HIGH
SPRING TENSION.
Repairs and adjustments
must be made by an
experienced door
professional or mechanic,
using proper tools and
instructions.
DO NOT REMOVE, COVER OR
PAINT THIS LABEL.

© Copyright 2010 Wayne-Dalton,

262484 REV1 01/08/10

a Division of Overhead Door Corp.

®

Plus tag(s)

Drawbar operator

bracket label

Residential warning label

The warning label will either be on

the right or the left end stile.

Torsion spring tag(s)

(one per spring)

HIGH SPRING TENSION CAN CAUSE
SERIOUS INJURY OR DEATH.

DO NOT adjust, repair or remove springs or parts to

which springs are connected, such as steel brack­ets, cables, wood blocks, fasteners or other parts of
the counterbalance system.

Adjustments or repairs must ONLY be made by a
trained door systems technician using proper tools
and instructions.

DO NOT remove, cover or paint over this tag. Prod­uct user should inspect this tag periodically for
legibility and should order a replacement tag from
the door manufacturer, as needed.

©Copyright 2010 Overhead Door Corporation

102081 REV2 06/24/2010

WARNING

The adjacent bottom corner
bracket and all cable
retention features including
milford pins, cotter pins, &
clevis pins are under HIGH
SPRING TENSION.
Repairs and adjustments
must be made by an
experienced door
professional or mechanic,
using proper tools and
instructions.
DO NOT REMOVE, COVER OR
PAINT THIS LABEL.

© Copyright 2010 Wayne-Dalton,

262484 REV1 01/08/10

a Division of Overhead Door Corp.

16

Warranty

Limited Warranty

Models 9100, 9405 and 9605

Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants to the original purchaser of the Models 9100, 9405 and 9605 (“Product”), subject to
all of the terms and conditions hereof, that the Product and all components thereof will be free from defects in materials and workmanship for the following period(s) of
time, measured from the date of installation:

LIMITED LIFETIME WARRANTY* on the Product sections against:

• Peeling, cracking, or chalking of the original factory-applied coating on the steel sections of the Product.

• The Product becoming inoperable due to rust-through of the steel skin from the core of the Product section, caused by cracking, splitting, or other deterioration
of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.

• The Product hardware (except springs) and the tracks.

ONE (1) YEAR on those component parts of the Product not covered by the preceding provisions of this Warranty
*Limited Lifetime shall mean as long as the original purchaser owns the house in which the Product is originally installed.

• TWO (2) YEARS on the Model 9405 factory attached overlay material against peeling, cracking, chalking, fading or delamination.

Seller’s obligation under this warranty is specifically limited to repairing or replacing, at its option, any part which is determined by Seller to be defective during

the applicable warranty period. Any labor charges are excluded and will be the responsibility of the purchaser.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty is made to the original purchaser
of the Product only, and is not transferable or assignable. This warranty applies only to Product installed in a residential or other non-commercial application. It does not
cover any Product installed in commercial or industrial building applications. This warranty does not apply to any unauthorized alteration or repair of the Product, or to
any Product or component which has been damaged or deteriorated due to misuse, neglect, accident, failure to provide necessary maintenance, normal wear and tear,
acts of God, or any other cause beyond the reasonable control of Seller or as a result of having been exposed to toxic or abrasive environments, including blowing sand,
salt water, salt spray and toxic chemicals and fumes.

ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS
FOR A PARTICULAR PURPOSE, ARE LIMITED IN TIME TO THE APPLICABLE WARRANTY PERIOD REFLECTED ABOVE. NO WARRANTIES, WHETHER EXPRESS OR IMPLIED,
WILL APPLY AFTER THE LIMITED WARRANTY PERIOD HAS EXPIRED. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation
may not apply to you.

IN NO EVENT SHALL SELLER BE RESPONSIBLE FOR, OR LIABLE TO ANYONE FOR, SPECIAL, INDIRECT, COLLATERAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL
DAMAGES, even if Seller has been advised of the possibility of such damages. Such excluded damages include, but are not limited to, loss of use, cost of any substitute
product, or other similar indirect financial loss. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or
exclusion may not apply to you.

Claims under this warranty must be made promptly after discovery, within the applicable warranty period, and in writing to the authorized distributor or installer
whose name and address appear below. The purchaser must allow Seller a reasonable opportunity to inspect any Product claimed to be defective prior to removal or
any alteration of its condition. Proof of the purchase and/or installation date, and identification as the original purchaser, may be required. There are no established
informal dispute resolution procedures of the type described in the Magnuson-Moss Warranty Act.

• SELLER: _______________________________________________________________________

• SELLER’S ADDRESS: _______________________________________________________________________

_______________________________________________________________________

17

Thank you for your purchase.

PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE

If you need assistance, please call 1-866-569-3799 (press Option 1) and follow the prompts to
contact a customer service representative. They will be happy to handle any questions that you
may have.

After installation is complete, leave this Installation

Instructions And Owner’s Manual with the homeowner, or

fasten it near garage door for easy reference.