Wayne-Dalton TORSION SPRING 9400 User's Manual
Contents
1. LAG SCREW 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 INSTALLATION 7 7 RIGHT HAND CABLE Torsion Spring Assembly DRUM BLACK Tools Needed NOTE Right and left hand is always none determined from inside the garage looking out NOTE Identify the springs provided as either right hand wound red winding We cone which goes on the LEFTHAND com S S TORSION SIDE or left hand wound black winding D vee TUBE cone which goes on the RIGHT HAND di SIDE Facing the inside of the door lay the jT torsion tube on the floor Lay the spring gt lt NYLON CENTER with the black color coded winding _BRACKET BUSHING _ cone and the black color coded cable drum at the right hand end of the tube NYLON CENTER Lay the spring with the red color coded BRACKET BUSHING winding cone and the red color coded RIGHT HAND WOUND RED WINDING CONE cable drum at the left hand end of the LEFT HAND SIDE tube we LEFT HAND WOUND LEFT HAND CABLE R BLACK WINDING CONE NOTE The set screws used on all DRUM RED TORSION RIGHT HAND SIDE torsion counterbalance winding cones TUBE and cable drums are now colored red zT DO NOT identify right and left hand by the set screw color Slide the nylon center bushing onto the an t2. 2 1 4 20 x 5 8 CARRIAGE BOLTS TOP BRACKET SLIDE TOP SECTION 2 1 4 20 FLANGE HEX TOP SECTION 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 Tools Needed Power Drill 7 16 Socket Driver Tools Needed Power Drill 7 16 Socket Driver NOTE If you have a model 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 U Bar Asymmetrical NOTE If a 3 U Bar was installed in step 8 skip this step NOTE Model 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 ba
3. HEX HEAD LAG TOP OF FLAGANGLE SCREWS Fig 8 Fig 9 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 Tools Needed Recommended tools from page 5 Tools Needed Recommended tools from page 5 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 Extension Spring Removal Step 1 Raise the door to the fully open position and place vice clamps to the back legs of both vertical tracks below the bottom rollers to prevent the door from falling By opening the door you release most of the spring tension Carefully unfasten the S hook from the horizontal angle Remove cable sheave and extension spring Repeat for the other side If safety cables are running through the extension springs remove them also Remove parts from work area Step 2 Holding door in the open position remove the vice clamps be prepared to support the entire weight of the door Garage doors can weigh 200 400 pounds With assistance carefully lower the door by grasping the door firmly by it s lift handles Do not place fingers or hands near joints between sections or between bottom of door and floor Otherwise severe injury could result NOTE C
4. 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 OPTIONAL INSTALLATION 1 Trolley Operator Tools Needed A WARN NG SUITABLE MOUNTING OPERATOR RAIL OPERATOR MUST BE TESTED PED MEM Ne AT TIME OF INSTALLATION AND K MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD 4 LAID FLAT UNDER THE DOOR FAILURE TO ADJUST OPERATOR IF NECESSARY CAN RESULT IN A SEVERE OR FATAL INJURY IF NU YOUR OPERATOR IS EQUIPPED WITH A PHOTOELECTRIC EYE SYSTEM THEN THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A CLOSING DOOR OPENS IF OPERATOR PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED FAILURE TO MAKE ADJUSTMENTS IF NECESSARY CAN RESULT IN SEVERE OR FATAL INJURY T P ET op PERFORATED ANGLE 1 Install operator rail 1 2 to 1 1 2 13 38 mm above high arc of top S section of the door 9 OPERATOR 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 Attach door arm to operator bracket installed in Step 10 FRAMING MEMBERS mounting surface 2 x 6 lumber Attach operator rail to s
5. L SECTION FLAGANGL 2 1 4 20 FLANGE HEX NUTS 1 3 8 16 HEX NUT 1 3 8 16 X 3 4 HEX HEAD BOLT RM TRACK TOP TOP TOP SECTION WIZ HORIZONTAL TRACK 2 1 4 20 X 5 8 CARRIAGE BOLTS HORIZONTAL HORIZONTAL TOP ROLLER TOP BRACKET 2 1 4 20 FLANGE HEX NUTS 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 Tools Needed Power Drill 7 16 Socket Driver 9 16 Socket Ratchet Wrench 9 16 Wrench Tools Needed Power Drill 7 16 Socket Driver Level Tape Measure Pencil 1 4 Torx Bit Torsion End Bearing Brackets End bearing brackets are right and left Using the slots in the lower flange of the end bearing bracket align the bracket with the flagangle on top of the horizontal angle and secure the end bearing bracket to the horizontal angle using 2 3 8 16 x 3 4 hex head bolts and 2 3 8 16 nuts Once the bracket is secured to the horizontal angle secure the top of the end bearing bracket to the jamb using 2 5 16 x 2 lag screws Repeat for other side NOTE Right and left hand is always determined from inside the garage looking out
6. The mounting surface must be securely attached to the wall with four 4 3 8 anchors for masonry constructions or four 4 5 16 x 4 lag screws for wood WEATHER SEAL construction 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 WEATHER header and temporarily secure it to the header with equally spaced nails SEAL 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 X fT JAMB 1 8 TO 1 4 For fully adjustable track Align the header seal 1 8 to 1 4 inside the header and temporarily secure it to the header with equally spaced nails HEADROOM REQUIREMENT Next fit the jamb seals up tight against the header seal and 1 8 to 1 4 inside the jamb Temporarily secure the jamb seals with equally spaced TRACK TYPE TorqueMaster nails This will keep the bottom section from falling out of the opening during installation Space nails approximately 12 apart 15 Radius Track 11 3 4 12 Radius Track 10 1 2
7. self tapping screws when attaching the bottom flange of the operator bracket to U Bar 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 TOP OPERATOR FLANGE BRACKET E FRONT a CENTER LINE O ment Wer TOP SECTION WITH OR WITHOUT U BAR SECTION OPERATOR BRACKET 2 412 X 1 2 PHILLIPS HEAD SCREWS VICE CLAMP NOTE NOT REQUIRED FOR J STRUTS Q 1 4 14X5 8 SELF TAPPING SCREWS OPERATOR BRACKET OPERATOR BRACKET 4 1 4 14 X 5 8 SELF TAPPING SCREWS 6 1 4 14 X 5 8 SELF TAPPING SCREWS OPERATOR BRACKET INSTALLATION WITHOUT U BAR 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 Tools Needed Hammer Tape Measure Power Drill 7 16 Socket Driver Top Section 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 hinge
8. 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 36
9. DOOR HEIGHT page5 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 bearing 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 14 356 mm above the top of the opening for Torsion spring applications For low headroom applications the jambs should extend HEADROOM to the ceiling height Minimum side clearance required from the opening to Z the wall is 3 1 2 89 mm HEADER PA BACKROOM IMPORTANT Closely inspect existing jambs header and mounting surface Any wood found not to be sound must be replaced For Torsion spring applications a suitable mounting surface must be firmly attached to the wall above the header at the center of the opening The mounting surface must be 2 x 6 lumber minimum Select southern yellow pine lumber Do not use lumber marked as spruce pine fur or SPF
10. NOTE Do not permanently attach weather seal to the jamb at this time 12 Radius Track eung 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 BACKROOM REQUIREMENT properly If the door is to be motor operated 2 1 2 64 mm of additional headroom is required MANUAL MOTOR DOOR HEIGHT TRACK LIFT OPERATED NOTE 6 LHR Conversion Kit is available for 12 Radius only Contact your local Wayne Dalton dealer 6 5 6 6 70 12 15 Radius 9g 120 3 BACKROOM REQUIREMENT Backroom is defined as the distance needed 76 80 12 15 Radius from the opening back into the garage to allow the door to open fully 10 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 Installation IMPORTANT READ INSTRUCTIONS TITLED P4 REMOVING THE OLD DOOR ON PAGE 9 AND P5 PREPARING THE OPENING ON PAGE 10 BEFORE ATTEMPTING DOOR INSTALLATION 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 INSTAL
11. Required p Ps pd 1 8 7 16 3 16 POWER DRILL RATCHET WRENCH PENCIL LEVEL TAPE MEASURE mar SIR DRILL BITS JO OOS N APPROVED WINDING PHILLIPS HEAD SCREWDRIVER FLAT TIP SCREWDRIVER 1 4 TORX BIT BARS GLOVES A 7 16 1 2 9 16 7 16 SOCKET DRIVER 7 16 1 2 3 8 9 16 SAFETY GLASSES SOCKETS WRENCHES HAMMER VICE GRIPS VICE CLAMPS SAW HORSES PAIR STEP LADDER Removing An Old Door A WARNING IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED DO NOT ATTEMPT TO WORK ON IT BUT HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK OTHERWISE SEVERE OR FATAL INJURY COULD RESULT A WARNING DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO PREVENT UNINTENDED DOOR OPERATION OTHERWISE SEVERE OR FATAL INJURY COULD RESULT A WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE A POWERFUL SPRING RELEASING IT S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY A WARNING IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS OR SEVERE INJURY COULD RESULT A WARNING REMOVING AN EXISTING DOOR CAN BE DANGEROUS FOLLOW INSTRUCTIONS ON PAGES 6 10 REMOVING AN OLD DOOR PREPARING THE OPENING CAREFULLY OTHERWISE SEVERE OR FATAL INJURY COULD RESULT If you have an existing door follow the instructions to identify which counterbalance removal is necessary The process of removing an existing door begins by identifying it s coun
12. 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 on four and five section doors The INTERMEDIATE II SECTION can be identified by a 4 end hinge This section if always the 4th section from the bottom of the door on only five section doors 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 IG NG Ad p WARNING LABEL TOP SECTION iml irm INTERMEDIATE II SECTION 3 a WARNING LABEL ia INTERMEDIATE SECTION Pd LOCK SECTION P 1 L7 WARNING LABELS CNN BOTTOM SECTION eee SECTION SIDE VIEW i END HINGE INT USED ONLY ON FIVE SECTIONS BOTTOM BRACKET mJ Sac ASTRAGAL 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 Tools
13. local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www wayne dalton com Door Section Identification NOTE This provides an alternative method for identifying your door sections stack position 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 on four and five section doors The LOCK SECTION can be identified by a 2 end hinge This section is always the 2nd section from the bottom of the door on four and five section doors The INTERMEDIATE SECTION can be identified by a 3 end hinge Sections will have
14. screws one full turn IMPORTANT CHECK EACH CABLE MAKING SURE BOTH ARE SEATED PROPERLY ON THE CABLE DRUMS AND HAVE EQUAL CABLE TENSION Securing Door for Spring Winding Place vice clamps onto both vertical tracks just above the third roller This is to prevent the garage door from raising while winding torsion springs A WARNING FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY IMPORTANT DO NOT USE IMPACT GUN TO WIND SPRING S VICE GRIPS J JMB TORSION TUBE p NW LEFT CABL DRI PLACE VICE CLAMPS ABOVE 3RD ROLLER ON BOTH VERTICAL TRACKS VICE CLAMPS ATTACHED TO INNER RAIL OF TRACK 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 Winding Torsion Spring s Tools Needed Position a ladder slightly to the side of spring so that the winding cone is easily accessible yet your body is not Drill Bi in direct line with the winding bars e Check the label attached to the spring 7 16 Socket warning tag for the required number of Driver complete turns to balance your door Power Drill Phillips Head 6 6 Door Height Approx 7 Turns Screwdriver 70 Door Height Approx 7 1 2 Turns 8 0 Door Height Approx 8 3 4 Turns Windi
15. 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 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 formi
16. AL 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 A WARNING READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION IF IN QUESTION ABOUT ANY OF THE PROCEDURES DO NOT PERFORM THE WORK INSTEAD HAVE A QUALIFIED DOOR AGENCY DO THE INSTALLATION OR REPAIRS 3 12 13 14 15 16 READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS Wear protective gloves during installation to avoid possible cuts from sharp metal edges It is always recommended to wear eye protection when using tools otherwise eye injury could result Avoid installing your new door on windy days Door could fall during the installation causing severe or fatal injury Doors 12 0 wide and wider should be installed by two persons to avoid possible injury Operate door ONLY when it is properly adjusted and free from obstructions 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 DO NOT stand or walk under a moving door or permit anybody to stand or walk under an electrically operated door DO NOT place fingers or hands into open section joints when closing a door Use lift handles gripping points when operating door manually DO
17. ASTER SEARS GENIE CURVED STRAIGHT CURVED STRAIGHT OPERATOR MODELS QUANTUM CLASSIC LINEAR LIFTMASTER SEARS GENIE 30 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 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 hook up 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
18. Center Bearing Bracket Measure to locate the center of the door and mark a vertical pencil line on the mounting surface above the door to indicate the center line of the door Then measure from the center of the bearing in one of the end bearing brackets DOWN to the top of the door Using that dimension measure UP from the top of the door and mark a horizontal pencil line on the mounting surface intersecting the vertical pencil line Now align the edge of the center bearing bracket along the vertical pencil line on the mounting surface Center the bearing bracket on the horizontal line This will ensure the torsion tube is level between the center and end bearing brackets Attach the center bearing bracket in this location to the mounting surface using 2 5 16 x 2 lag screws and 1 5 16 x 2 tamper resistant lag screw IMPORTANT USE THE 5 16 X 2 TAMPER RESISTANT LAG SCREW ONLY IF MOUNTING SURFACE MOUNTED OVER MASONRY TAMPER RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF THE CENTER BEARING BRACKET 2 3 8 16 X 3 4 HEX HEAD BOLTS 2 5 16 X 2 MOUNTING SURFACE EQUAL DISTANCE p A BRACKET HORIZONTAL LINE CENTER OF END BEARING BRACKET CENTER BEARING MOUNTING va SURFACE 2 5 16 X Z 2 5 LAG SCREWS VERTICAL LINE HORIZONTAL LINE 1 5 16 X 2 TAMPER RESISTANT LAG SCREW Sia OR 1 5 16 X 2
19. D 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 Some States do not allow limitations on how long an implied warranty lasts so the above limitations may not apply to you 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 LAB
20. EN REMOVING THE END BRACKET AND DRIVE GEAR HOLD THE Step 7 Repeat Step 4 for the left hand A un DOMI side Holding the left hand end bracket LOCKING PLIERS steady with locking pliers carefully pry the end bracket off the winding shaft using a flat tip screwdriver Fig 7 Step 8 Remove the two 2 lag bolts attaching the center bracket assembly to ne header board Fig 8 7 PRY END BRACKET FROM WINDING Step 9 Lift the right hand side of the E SHAFT USING A FLAT TIP SCREW TorqueMaster Spring Tube and slide the DRIVER AND LOCKING PLIERS cable drum off Realign the groove in the Due winding shaft with the round notch in the IX flagangle and drape the counterbalance cable with drum over the flagangle Lift the left hand side of the TorqueMaster CENTER Spring Tube and slide the cable drum BRACKET REMOVE CABLE DRUM AND and winding shaft off Fig 9 Drape the ASSEMBLY WINDING SHAFT counterbalance cable with drum over the L flagangle Lift the TorqueMaster spring assembly off the flagangles and out of the doorway Unhook the counterbalance cables from the bottom brackets and p S N f remove all parts from the work area L JM yA NOTE The cable drums may be difficult to remove If so twist the cable drum to aid a 715 uff in removal lb TTORQUEMASTER NOTE Continue with P4 on page 9 after E completing this step 2 5 16 X 1 5 8 DRAPE CABLE aeance Minaa
21. LING PRODUCTS ON UNTREATED LUMBER NOTE It is recommended that 5 16 x 2 lag screws be pilot drilled using a 3 16 drill bit and 1 4 x 2 lag screws and 1 4 x 1 1 2 lag screws be pilot drilled using a 1 8 drill bit prior to fastening NOTE If you have riveted track skip these steps 1 through 2 and proceed to step3 z 3 E E 7 Attaching Fully Adjustable Flagangle to Vertical Track FULLY Tools Needed Hand tighten the flagangle to the L FUGNGE vertical track using 2 1 4 20 x 5 8 carriage bolts and 2 1 4 20 flange hex nuts Secure the flange nuts after 2 1 4 20 flagangle spacing is complete Step 11 FLANGE HEX NUTS None 2 1 4 20 X 5 8 CARRIAGE BOLTS VERTICAL Fd TRACK 11 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 Installing Q 1 Jamb Brackets Tools Needed Measure the length of the vertical tracks Using the jamb bracket schedule determine the placement of the jamb brackets for your door height and track type None 3RD SET HOLES To install the jamb brackets align the twistlock tab on the quick install jamb E bracket with the quick install feature in the track and turn the bracket perpendi
22. LONG WITH ANY U BAR S INITIALLY PROVIDED WITH THE DOOR IT IS THEN UNNECESSARY TO FURTHER REINFORCE THE TOP SECTION OF THIS WAYNE DALTON DOOR WHEN ATTACHING A TROLLEY TYPE OPERATOR AS LONG AS THE INSTALLATION OF THE OPERATOR IS ACCORDING TO WAYNE DALTON S INSTRUCTIONS AND FORCE SETTINGS ARE 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 NO U BAR INSTALLED If a U Bar is not installed on the top section continue with the steps below Attach 4 1 4 14 x 5 8 self tapping screws to the front of the operator bracket Next attach 2 1 4 14 x 5 8 self tapping screws to the bottom flange of the operator bracket 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 used to attach the U Bar instead of the 2 1 4 14 x 5 8
23. MBERS M iy USING 2 5 16 X 1 5 8 HEX HEAD LAG SCREWS TO CEILING MEMBER AND PARALLEL TO WIDTH OF DOOR HORIZONTAL TRACK BOLT MUST EXTEND INTO 4 THE TRACK TO SERVE AS A ROLLER STOP eo0oococooocloocooo boooo poo o o PERFORATED ANGLE 3 5 16 BOLTS amp NUTS 27 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 INSTALLATION Tools Needed Power Drill 7 16 Socket Driver Tools Needed Power Drill 1 8 Drill Bit 28 Side Lock 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 16 Pull Rope A 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
24. 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 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 On electrically operated doors pull down ropes must be removed and locks must be removed or made inoperative in the open unlocked position Top section of door may need to be reinforced when attaching an electric opener Check door and or opener manufacturer s instructions VISUALLY inspect door and hardware monthly for worn and or broken parts Check to ensure door operates freely Test electric opener s safety features monthly following opener manufacturer s instructions 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 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 onli
25. OR 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 War ranty 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 Manu facturer 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 Some States do not allow the exclu
26. PPROVED unbalanced door such as this can WINDING BARS cause garage door opener operation problems A 25 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 INSTALLATION WINDING CONE 2 1 Rear Support DOOR IN THE UP POSITION Tools Needed A WARNING DH Ratchet Wrench KEEP HORIZONTAL TRACK up Socket PARALLEL AND WITHIN 3 4 MAXIMUM OF DOOR EDGE wo Wrench OTHERWISE DOOR COULD FALL RESULTING IN SEVERE INJURY OR 2 Vice Clamps DEATH 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 track is not yet supported A WARNING RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE SEVERE INJURY OR DEATH 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
27. VIEW SHOULD A REPLACEMENT SPRING WARNING TAG y BE REQUIRED CONTACT WAYNE DALTON CORP FOR FREE REPLACEMENTS TORSION SPRING INSTALLATION CENTER BEARING BRACKET 2 3 8 16 NUT TORSION SPRING 2 3 8 16 X 1 1 2 HEX HEAD BOLT 23 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 Tools Needed Vice Grips 3 8 Wrench Tools Needed 2 Vice Clamps 24 Counterbalance Cables Release the vice grips from the ends of the cables and thread the counterbalance cables around the back side of the cable drums and verify that there are no cable obstructions Hook the cables into the drums Slide the left hand cable drum against the left hand end bearing bracket and tighten the set screws in the drum to 14 15 ft lbs of torque Once set screws contact the tube tighten screws one full turn Rotate the left hand drum and torsion tube until cable is taut Attach vice grips to torsion tube and brace vice grips against jamb to keep cable taut Slide the right hand cable drum against the right hand end bearing bracket and rotate drum until cable is taunt Tighten set screws in right hand cable drum to 14 15 ft Ibs of torque Once set screws contact the tube tighten
28. Wayne Dalton 9100 9400 9600 Torsion 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 any of the procedures do not perform the ae oe 9 work Instead have a qualified door agency Hope www wayne dalton com do the installation or repairs Copyright 2009 Wayne Dalton Corp Part No 290771 REV4 08 03 2009 Table of Contents Important Safety Instructions esses 2 Package Gorntents oos e nensem 3 4 DoonmSecHonidentficationeeee E 4 iToo S Bequitedeseseess eR ODE E 5 PrelnstallatiOm ee a E E E A E 5 10 Removing The OldiBoor 5 9 ae oe tine UAE Opening 10 installations a on er eees 11 27 OOE S E EIOS eee eee eee 28 32 SidelOck a T 28 Pu Ropa e a e e thro 28 Stepiplato rere eee E EI TRE 29 Trolley Installation for Standard Lift 30 Trolley Installation for Low Headroom 31 TrollgyiODeratofee eee aster etter cst se 32 Maintenance ees eo E 33 34 Cleaning eee eee ee SS eini Ne MEOS oeras 33 34 Maa re re A e AE 35 pealenkocatoniMmormarnom a a 36 Definition of key words used in this manual A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN SEVERE OR FAT
29. 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 Manu facturer s published list pricing at time of claim and you must pay this amount This Limited Warra
30. alton com Tools Needed 9 16 Socket 7 16 Socket Ratchet Wrench 9 16 Wrench Level Hammer Tools Needed 7 16 Wrench 20 Attaching Horizontal Track to Adjustable Flagangle 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 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 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 A WARNING DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR AS OUTLINED IN STEP 21 OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY 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 roller slide to the top bracket base INCORRECT Pu SECTION
31. arm to accomplish trolley settings as shown in FIG 3 3 through FIG 3 4 Attach door arm to trolley and align the appropriate door arm hole with the hole in the door operator bracket Insert 1 hex head bolt through hole of operator bracket and door arm Install 1 LOCKING hex nut and just tighten until snug A WARNING FAILURE TO USE LOCKING NUT CAN RESULT IN ARM RELEASING AND POSSIBLE RESULTING IN PROPERTY DAMAGE AND OR PERSONAL INJURY QUANTUM AND CLASSIC OPERATORS REQUIRE 1 3 8 16 x 1 hex bolt and 1 3 8 16 LOCKING hex nut as shown in FIG 3 5 LINEAR LIFTMASTER SEARS GENIE OPERATORS REQUIRE 1 5 16 18 x 1 hex bolt and 1 5 16 18 LOCKING hex nut as shown in FIG 3 5 TYPICAL 1 2 1 ABOVEHIGHARC TORQUEMASTER HIGH ARC COUNTERBALANCE LINE Dil rl TOP SECTION LOW ee lees HEADROOM 1 TRACK t I VERTICAL FROM CENTER LINE STEP 12 HEADER FIG 3 2 CURVED CUT STRAIGHT ARM TO ACCOMPLISH TROLLEY SETTING FIG 3 4 OPERATOR BRACKET d STRAIGHT ARM OPERATOR HOOK UP CHART FOR LOW HEADROOM TYPE OF ARM BEING USED OPERATOR MODELS PREFERRED REF ILLUSTRA OPTIONAL REF ILLUSTRA HOOKUP TIONSABOVE HOOKUP TIONS ABOVE CURVED QUANTUM CLASSIC soeur ETE STRAIGHT rss ues omwen mess we wa Mews sma ei smon men soe er ee Smo e 31
32. carriage bolt and nut 1 Cem zz STEP PLATE MS HEX NUT STEP PLATE INSIDE OPTIONAL INSTALLATION ASSEMBLED STEP PLATE 8 SCREWS 29 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 Trolley Installation for Standard Lift 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 hook up from trolley to operator bracket NOTE Refer to your operator manual for specific de
33. cular to the track so the mounting flange is toward the back flat leg of the track MA QI JAMB BRACKET A LA 1ST SET HOLES QUICK INSTALL FEATURE JAMB BRACKET SCHEDULE 1ST SET 2ND SET 3RD SET DOOR HEIGHT 8 4 SECTION QUB a MIDDLE auB 5 MIDDLE QUJB 6 MIDDLE secnom que 3 Bottom auB 5 Bottom QuB e BOTTOM 12 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 COUNTERBALANCE CABLE BOTTOM SECTION HINGE TUBE Tools Needed IMPORTANT RIGHT AND LEFT HAND None IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT NOTE For door section identification see page 4 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 MILFORD PIN at 1 end hinge at the top of the bottom section Repeat for other side BOTTOM BRACKET NOTE Verify astragal bottom seal is aligned with door section If there is more than 1 2 excess astragal on BOTTOM either side trim astragal even with door SECTION
34. listed number of turns 6 0 Door Heigh 6 3 Door Heigh 6 5 Door Heigh 6 6 Door Heigh t urns t t t 6 8 Door Vari t t t t t 1 2 turns turns turns 1 2 turns 1 2 turns turns 1 2 turns turns 6 9 Door Heigh T 0 Door Heigh T 3 Door Heigh T 6 Door Heigh T 9 Door Heigh 1 2 turns 8 0 Door Height 18 turns CAUTION DO NOT USE IMPACT GUN TO UNWIND SPRINGS IMPORTANT DO NOT REFERENCE THE COUNTER COVER WHEN COUNTING THE NUMBER OF TURNS BEING UNWOUND ON THE SPRING BUT FOLLOW THE INSTRUCTIONS ABOVE Step 3 Verify that spring tension has been released by pulling the counterbalance cable on the right hand cable drum away from the header Fig 3 If spring tension has been released the cable will be loose In addition the TorqueMaster Spring Tube should be free to rotate in either direction 4 4 5 5 5 5 6 6 7 7 1 1 1 1 1 1 1 1 1 1 1 LOOSEN LOCK RIGHT HAND CABLE DRUM TORQUEMASTER SPRING TUBE PRY COUNTER GEAR AND COUNTER COVER FROM END BRACKET USING FLAT TIP SCREWDRIVER COUNTER GEAR COVER RIGHT HAND END BRACKET PLACE MARK ON END BRACKET AND DRIVE GEAR TOOTH BEFORE UNWINDING SPRINGS END BRACKET RIGHT HAND WINDING BOLT HEAD ELECTRIC DRILL WITH 7 16 HEX DRIVER DO NOT USE IMPACT GUN CHECK CABLE TENSION COUNTER GEAR COUNTER Please Do Not Return This Product To The Store Contact y
35. ne at www wayne dalton com NOTE DEPENDING ON THE DOOR MODEL SOME PARTS Package Contents LISTED WILL NOT BE SUPPLIED IF NOT NECESSARY REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR 2 END BEARING BRACKETS RH LH fe 7o ot DOOR SECTIONS AS REQUIRED 0 00000 2 HORIZONTAL TRACKS WITH ATTACHED HORIZONTAL ANGLE RH LH 2 SPRINGS WITH CONES RH LH TORSION TUBE ZA LP EN LA WEATHER SEAL amp 1 OPERATOR Q l JAMB BRACKETS ROLLERS 2 CABLE DRUMS NAILS IF INCLUDED BRACKET AS REQUIRED AS REQUIRED TAJ W RH LH FLAGANGLES 2 TOP BRACKET CENTER BEARING 2 COUNTERBALANCE CABLES 1 NYLON CENTER RH LH TRACKS SLIDES BRACKET BUSHING 2 FULLY ADJUSTABLE 2 VERTICAL ASYMMETRICAL U BAR 2 TOP BRACKET 6 SCREW EYE AND PULL MANUAL 2 3 8 16 IF INCLUDED IF INCLUDED ROPE IF INCLUDED HEX NUT 1 4 20 FLANGED HEX 1 4 14 X 5 8 SELF TAPPING 1 4 20 X 11 16 SELF DRILLING 4 1 4 20 X 5 8 3 8 16 X 3 4 NUT AS REQUIRED SCREW AS REQUIRED SCREW AS REQUIRED CARRIAGE BOLT HEX HEAD BOLT VNANANINTINAINAINAININAINAINAINAINAINANAINAN 3 8 16 X 1 1 2 HEX HEAD BOLT 5 16 X 2 HEX HEAD LAG SCREW 5 16 X 2 TAMPER PROOF HEX HEAD LAG AS REQUIRED SCREW AS REQUIRED Please Do Not Return This Product To The Store Contact your
36. ng 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 33 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 MAINTENANCE Painting Continued NOTES 1 Repainting of finish painted steel doors cannot be warranted as this condition is totally beyond the door manufacturer s cont
37. ng Bars A 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 Alternately inserting the winding bars into the holes of the spring s winding cone rotate the winding cone upward toward ceiling 1 4 turn at a time until the required number of complete turns for your door height is achieved As the 2 d APPROVED last 1 4 turn is achieved securely hold th WINDING BARS winding bar while tightening both set screws in winding cone to 14 15 ft Ibs of torque Once set screws contact the tube tighten screws one full turn Carefully remove winding bar from winding cone Proceed to wind the second spring in the same manner While holding the door down to prevent it from rising unexpectedly in the event the spring s were overwound carefully remove the locking clamps from the torsion tube and the vertical tracks IMPORTANT CAUTIOUSLY REMOVE LOCKING PLIERS FROM THE TORSION TUBE AND LOCKING CLAMPS FROM THE VERTICAL TRACKS Adjustments to the required from the SPRING number of turns stated may be necessary If door raises off floor under spring tension alone Reduce spring tension until door rests on the floor If the door is hard to raise or drifts down on its own add spring tension An U WINDING A
38. nty 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 compo nents 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 DEFINE
39. ontinue with P4 on page 9 after completing this step Removing the Old Door Having removed the counterbalance system the door can now be disassembled Start by first removing the top row of hinges With assistance hold the top section to keep it from falling and remove the top brackets With assistance lift the top section out of the opening and remove it from the work area Repeat for all remaining sections After door is disassembled unbolt both track assemblies from the jambs and remove all material from the work area You can neatly dispose of the old door by placing it in the carton of your new door Clean up area and complete Preparing the Opening P5 on page 10 before installing the new door REMOVE LAG SCREW a FROM SAFETY CABLE IF INSTALLED REPEAT FOR OPPOSITE SIDE BOTTOM SECTION DOOR OPEN CAREFULLY REMOVE S HOOK AND COUNTERBALANCE CABLE REPEAT FOR THE OPPOSITE SIDE HORIZONTAL ANGLE TOP BRACKET lg HORIZONTAL TRACK local yellow pages business listings or go to the Find a Dealer section online at www wayne dalton com PRE INSTALLATION SUITABLE MOUNTING Preparing the Opening SURFACE 2 X 6 HEADER BOARD LUMBER MINIMUM FAILURE T 2 X 6 LUMBER Tos Needed MATIS N cecuncuyartach a Cree Recommended SUITABLE MOUNTING PAD TO STRUCTURALLY 2 ET tools from SOUND FRAMING COULD CAUSE SPRINGS TO p
40. or Apply locking pliers to track above third roller Insert a winding bar into the winding cone Push upward on the winding bar while carefully loosening the set screws in the winding cone BE PREPARED TO SUPPORT THE FULL FORCE OF THE TORSION SPRING ONCE THE SET SCREWS ARE LOOSE Carefully adjust spring tension 1 4 turn Retighten both set screws in the winding cone and repeat for the other side Recheck door balance DO NOT ADJUST MORE THAN 1 2 TURN FROM THE RECOMMENDED NUMBER OF TURNS If door still does not balance correctly contact a qualified door agency If the door still does not operate easily lower the door into the closed position UNWIND THE SPRING S FULLY Refer to P1 on page 6 Torsion Spring Removal For Standard Lift and recheck the following the items 1 Check the door for level 2 Check the torsion tube for level 3 Check the track spacing 4 Check the counterbalance cables for equal tension 5 Check the track for potential obstruction of the rollers 6 Clamp locking pliers onto track and rewind springs IMPORTANT IF DOOR STILL DOES NOT OPERATE PROPERLY THEN CONTACT A QUALIFIED DOOR AGENCY gt SOUND FRAMING MEMBERS 2 PERFORATED ANGLE BOLTED USING 2 5 16 X 1 5 8 HEX HEAD LAG SCREWS TO CEILING MEMBER AND PARALLEL TO WIDTH OF DOOR HORIZONTAL TRACK BOLT MUST EXTEND INTO z4 THE TRACK TO SERVE AS v A ROLLER STOP M T SOUND FRAMING ME
41. or lowering while installing the rear support VERTICAL TRACK 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 with door NOTE If rear supports are to be installed over drywall use 5 16 x 2 hex head lag screws Adjust weather seal if necessary Now permanently attach the weather seal to both door jambs and header Temporarily attached in PREPARING THE OPENING on page 10 Avoid pushing weather seal stop too tightly against face of door HORIZONTAL TRACK 26 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 Tools Needed Rear Support Continued A 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 To adjust spring tension fully close do
42. orsion tube followed by the springs and cable drums The nylon center bushing springs and cable drums must be CENTER positioned as shown With assistance pick up the torsion TORSION assembly and slide one end of the tube ASSEMBLY through one end bearing bracket Lay the torsion tube into the center bearing bracket and slide the other end of the tube into the opposite end bearing bracket Position the torsion tube so MR that equal amounts of the tube extend KY TORSION from each end bearing bracket gt END ASSEMBLY BEARING BRACKET 22 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 Nylon Center Bushing Tools Needed Slide the nylon center bushing into the TORSION stationary spring cone at the end of the SPRING 9 16 Socket spring and align the stationary spring cone s with the holes in the center Ratchet Wrench bearing bracket Secure the spring s to CENTER BEARING the center bearing bracket with BRACKET 9 16 Wrench 2 3 8 16 x 1 1 2 hex head bolts and 2 3 8 16 nuts IMPORTANT SPRINGS UNDER TENSION CAN BE DANGEROUS IMPORTANT THE SPRING WARNING STARCRAES TAG S SUPPLIED MUST BE SECURELY SPRING CONE ATTACHED TO THE STATIONARY SPRING CONE IN PLAIN
43. our 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 PRE INSTALLATION TorqueMaster Spring Removal continued Tools Needed If the counterbalance cable is still taut and the TorqueMaster Spring Tube is difficult to rotate that is an indication that spring Recommended tension still exists on the left hand spring tools from Repeat Steps 1 and 2 for releasing spring page 5 tension on the left hand side Step 4 Using a flat tip screwdriver pry the counter gear and counter cover REMOVE TOP from the right hand end bracket Fig 4 LAG SCREW on previous page Discard the counter gear and counter cover On double spring applications repeat for left hand side Step 5 Remove the upper 5 16 x USE LOCKING PLIERS 1 5 8 lag screw from the right hand end TO HOLD END BRACKET bracket Fig 5 Attach locking pliers to the upper portion of the end bracket and hold the housing steady while removing REMOVE 10 the lower 5 16 x 1 5 8 lag screw and EEX PHILLIPS HEAD 10 x 1 2 phillips head screw from the TESS SCREW end bracket Fig 6 Step 6 Holding the right hand end bracket steady with locking pliers carefully pry the end bracket and drive gear off the winding shaft using a flat tip REMOVE screwdriver Fig 7 BOTTOM LAG amp CAUTION THE WINDING SHAFT MAY SEREN ROTATE WH
44. r 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 approximately 18 self tapping screws per 18 u bar 4 1 4 20 X 11 16 U BAR SELF DRILLING SCREWS TOE DOUR SEC I U BAR 1 4 14 X 5 8 SELF TAPPING SCREWS 2 1 4 20 X 11 16 ELF DRILLING SCREWS TOP DOOR SECTION OPERATOR BRACKET INSTALLED IN STEP 10 INSTALLATION OPERATOR BRACKET INSTALLED IN STEP 10 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 Tools Needed Power Drill 7 16 Socket Driver Vice Clamps Phillips Head Screwdriver 18 Operator Bracket NOTE Operator bracket must be mounted and secured prior to installing top section NOTE If an idrive operator is to be installed the operator bracket is not required to be installed IMPORTANT WHEN INSTALLING A TROLLEY TYPE OPERATOR ON 9100 9400 AND 9600 SERIES DOORS A WAYNE DALTON TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION A
45. r to prevent the door from lifting as you unwind the springs Use only approved winding bars available from your dealer Do not use undersized steel rods screw drivers or anything else to unwind the springs Position the ladder just off to the side of the winding cone The winding cone should be easy to reach without putting your body directly in front of it Step 2 Insert a winding bar into one of the holes in the winding cone Exert upward pressure Using caution loosen the two 2 set screws in the winding cone Be prepared to support the full torsional force of the spring when the set screws are loosened Step 3 Once set screws are loose slowly and carefully lower the winding rod until it rests against the door Insert other winding bar into the upper hole Push up and remove lower bar Carefully lower upper winding bar 1 4 turns at a time until it rests against the door Repeat process until all tension is relieved If your door is equipped with two 2 torsion springs follow the same procedure to relieve tension on the second spring Step 4 Remove vice clamps from tracks unbolt torsion shaft assembly and remove from work area NOTE Continue with P4 on page 9 after FIRMLY HOLD WINDING BARS AND completing this step CAUTIOUSLY LOOSEN SET SCREWS 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 busine
46. racket tighten the lag screw securing the bottom jamb bracket to the jamb to maintain the 5 8 spacing Repeat for the right hand side JAMB BRACKET VERTICAL TRACK LAG SCREW LOCATIONS oc Og e l FLAGANGLE 5 16 X 2 s LAG SCREWS VERTICAL TRACK ASSEMBLY BOTTOM SECTION BOTTOM SECTION 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 Stacking Sections Tools Needed NOTE For door section identification Power Drill see page 4 7 16 Socket NOTE Make sure hinge leafs are Driver 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 Keep sections vertically aligned and fasten hinges to connect the sections using 1 4 14 x 5 8 self tapping screws Repeat for other section s except top section INSTALLATION IMPORTANT END HINGES HAVE 2 SCREWS AND INTERMEDIATE HINGES HAVE 3 SCREWS NOTE Install lock at this time sold separately See instr
47. rol 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 34 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 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
48. s last Refer to Step 6 When installing a door with a torsion 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 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 Complete the vertical track installation by securing the center jamb bracket s and tightening the other lag screws Push the vertical track against the rollers so that the rollers are touching the deepest part of the curved side of the track see illustration Tighten all the carriage bolts and nuts Repeat for opposite side DOOR WIDTH 3 3 8 TO 3 1 2 NAIL TOP SECTION FLAGANGLE dq VERTICAL TRACK ROLLER ROLLER AGAINST VERTICAL TRACK 1 11 16 TO 1 3 4 TOP SECTION ios Ll 19 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 d
49. section y INSTALLATION Bottom Section Tools Needed Before installing the bottom section Level the weather seal may not be included must be installed see PREPARING THE OPENING on page 10 Center the bottom section in the door EAL opening Level section using wooden a WEATHER S shims under the bottom astragal if Nl necessary DOOR OPENING LEVEL BOTTOM SECTION WOODEN SHIMS IF NECESSARY 13 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 Tools Needed 3 16 Drill Bit Power Drill 7 16 Socket Driver Tape Measure Level 2 Vice Grips 14 Vertical Track IMPORTANT THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT THE VERTICAL TRACK ON THE SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM Position the left hand vertical track assembly over the rollers of the bottom section Make sure the counterbalance cable is located between the rollers and the door jamb Drill 3 16 pilot holes for the lag screws Loosely fasten jamb brackets and flagangle to the jamb using 5 16 x 2 lag screws On the bottom jamb b
50. sion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to 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 This Limited Warranty gives you specific legal rights and you may also have other rights which may vary from State to State 35 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 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
51. ss listings or go to the Find a Dealer section online at www wayne dalton com Tools Needed Recommended tools from page 5 TorqueMaster Spring Removal A TorqueMaster spring system can be identified by the end brackets For single spring applications the right hand end bracket will always have a drive gear counter gear counter cover and a winding bolt head The left hand end bracket will have no gears counter cover or winding bolt head The hole for the winding bolt head will be plugged For double springs both the right hand and left hand end brackets will always have a drive gear counter gear counter cover and a winding bolt head IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT Step 1 If you have a black counter cover Place a mark on the drive gear tooth and an adjacent mark on the right hand end bracket Fig 1 Loosen the lock nut using a 7 16 wrench and continue with step 2 If you have a gray counter cover Loosen the lock nut using a 7 16 wrench and continue with step 2 Step 2 Using an electric drill High torque gear reduced to 1300 rpm preferred with a 7 16 hex head driver unwind the right hand winding bolt head counterclockwise Fig 2 and count the number of turns the mark on the drive gear passes the adjacent mark on the end bracket Referencing the chart below by door height stop unwinding the spring once the counted turns have reached the
52. tails 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 Attach door arm to trolley and align the appropriate door arm hole with the hole in the door operator bracket Insert 1 hex head bolt through hole of operator bracket and door arm Install 1 LOCKING hex nut and just tighten until snug A WARNING FAILURE TO USE LOCKING NUT CAN RESULT IN ARM RELEASING AND POSSIBLE RESULTING IN PROPERTY DAMAGE AND OR PERSONAL INJURY QUANTUM AND CLASSIC OPERATORS REQUIRE 1 3 8 16 x 1 hex bolt and 1 3 8 16 LOCKING hex nut as shown in FIG 2 6 LINEAR LIFTMASTER SEARS GENIE OPERATORS REQUIRE 1 5 16 18 x 1 hex bolt and 1 5 16 18 LOCKING hex nut as shown in FIG 2 6 DETERMINE THE WAYNE DALTON TRACK RADIUS BEING USED HORIZONTAL TRACK 12 OR 15 TYPICAL 1 2 HIGH ARC 1 ABOVE HIGH ARC TORQUEMASTER COUNTERBALANCE STRAIGHT CURVED STEP 12 l e om 1 7 VERTICAL CENTER LINE Z ACCOMPLISH HEADER TROLLEY o Ta SETNG CUT STRAIGHT ARM TO me FIG 2 4 LOCKING RENAL OPERATOR HEX BOLT CUT STRAIGHT ARM TO ACCOMPLISH TROLLEY SETTING FIG 2 5 REF ILLUSTRATIONS ABOVE LIFTM
53. terbalance system If you are not removing an existing door proceed to PREPARING THE OPENING on page 10 Generally you will find three 3 types of counterbalance systems Extension Spring Wayne Dalton exclusive TorqueMaster and Torsion counterbalance system see pages 6 9 For more technical information regarding the opening preparation installation and use of your garage door and opener you can go to www dasma com and click on Publications and then Technical Data Sheet 5 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 PRE INSTALLATION Torsion Spring Removal For Standard Lift Tools Needed AMY NTT TORSION SPRING ASSEMBLY Recommended FAILURE TO USE APPROVED tools from WINDING BARS CAN CAUSE SPRING page 5 ENERGY TO BE RELEASED SUDDENLY RESULTING IN SEVERE OR FATAL INJURY A WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE A POWERFUL SPRING RELEASING IT S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY Do not release the torsion spring tension unless you are a qualified and experienced door technician Instead have a professional door agency release the tension Step 1 Close the door and place vice clamps on the back legs of both vertical tracks above the third rolle
54. 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 e Q 4 1 4 20 X 11 16 SELF DRILLING SCREWS NO 6 SCREW EYE 1 8 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 os Step Plate Tools Needed Make one mark 1 25 mm up from Tm the center of bottom edge of the bottom Hive Tall Bit section and another mark 2 3 16 56 Power Drill mm up from the first mark 7 16 Wrench 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 STEP PLATE Use the screw size shown below for BASE your model door 1 4 20 X 5 8 CARRIAGE BOLT a 8 x 3 4 screw for Model 9100 b 8 x 1 screw Model 9600 Tighten 1 4 20
55. uctions in OPTIONAL SIDELOCK INSTALLATION on page 28 2 1 4 14 X 5 8 a TAPPING SCREWS 3 1 4 14 X 5 8 SELF TAPPING SCREWS True INTERMEDIATE HINGES 15 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 1 Top Brackets Tools Needed NOTE This step may be pre assembled 16 Power Drill on some models 7 16 Socket To install the L shaped top brackets Driver align the top holes in the top bracket base with a the second set of holes in the endstile for 14 radius track b the first set of holes in the endstile for 10 amp 12 radius track Fasten using 4 1 4 14 x 5 8 self tapping screws Secure 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 1ST SET 10 amp 12 RADIUS TOP SECTION EN 2ND SET afa 4 1 4 14 x 5 8 O SELF TAPPING 14 RADI a SCREWS L TOP BRACKET BASE
56. uitable N minimum LT Attach operator to ceiling using perforated angle IMPORTANT ANGLES MUST BE l 4 SECURELY ATTACHED TO SOUND z i PERFORATED ANGLE FRAMING MEMBER S 32 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 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
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