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Wayne-Dalton 9600 Garage Door Opener User Manual

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1. ROLLER TOP SECTION 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 Tools Needed NOTE If you have a model 9400 9600 Series door with windows in the top section or 9100 Sonoma 8 high skip this step and complete Step 11 Power Drill 7 16 Socket Driver NOTE Model 9100 Series door over 13 wide require a 3 U Bar supplied 2 Saw Horses Place the 3 u bar over the top rib Fasten each end of the u bar to the endcap 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 20 x 5 8 self tapping screws one 6 to the left and one 6 to the right of the center of the door section NOTE After completing this step continue with Step 12 U Bar Asymmetrical Tools Needed NOTE If a 3 U Bar was installed in Step Power Drill 10 skip this step 7 16 Socket NOTE Model 9400 9600 glazed top Driver doors 13 0 wide or greater will be supplied with a 3 asymmetrical u bar for the top section Place the 3 asymmetrical u bar over the top rib Fasten each end of the u bar to the endcap with 2 1 4 20 x 11 16 self drilling screws Fasten center of the u bar as shown
2. 5 ai NOTE Depending on your setup you may or may not have to cut straight arm to accomplish trolley settings as shown in m EMT FIG 2 4 through FIG 2 5 _ OPERATOR Attach door arm to trolley and align the appropriate door arm AR SSA BRACKET 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 CUT STRAIGHT ARM TO A WAR N I N G E FAILURE TO USE LOCKING NUT CAN RESULT IN ARM RE SETTING LEASING AND POSSIBLE RESULTING IN PROPERTY DAMAGE AND OR PERSONAL INJURY OPERATOR HOOK UP CHART STANDARD LIFT FOR 12 RADIUS air AND Oi ASIC OPERATORS RERIIRE OPERATOR HOOK UP CHART STANDARD LIFT FOR 12 RADIUS 0 M 16x 1 hex boltond 3 8 18 LOCKING hex mt as shown in FIG 2 6 esenwcuesc cwosmuwr F amp 25 uw sm F amp 24 LINEAR LIFTMASTER SEARS GENIE OPERATORS omersmer mex REQUIRE SEARS 1 5 16 18 x 1 hex bolt and 1 5 16 18 LOCKING hex e cumwep smw F amp 25 nut as shown in FIG 2 6 OPERATOR HOOK UP CHART STANDARD LIFT FOR 15 RADIUS OPERATOR MODELS QUANTUM CLASSIC LINEAR LIFTMASTER SEARS GENIE 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 busin
3. ES gt D gt z KEY SLOT HORIZONTAL QUICK INSTALL qo TAB O VERTICAL TRACK 3 8 16 X 3 4 TRUSS HEAD BOLT ei DOOR WIDTH X 3 3 8 TO 3 1 2 1 716 TO 1 3 4 2 PTS E e TOP SECTION EJ pen Z ep m QUICK INSTALL TAB HORIZONTAL TRACK KEY al VERTICAL l O TRACK N S 3 8 16 HEX NUT HORIZONTAL ANGLE 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 Attaching Adjustable Flagangle to Horizontal Track NOTE If quick install flagangles were installed in Step 14 skip this step and continue with Step 16 If not complete this Tools Needed 7 16 Socket 9 16 Socket Ratchet Wrench 9 16 Wrench Level FLAT TIP SCREWDRIVER Step To install horizontal track place the curved end over the top roller Align the bottom of the horizontal track with the vertical track Hand tanten the horizontal track to the flagangle with 2 1 4 20 x 9 16 large head ribbed track bolts or stud plate i included and 2 1 4 20 flange hex nuts A WARNING DO NOT RAISE DOOR
4. Apply emergency disconnect label next to the mounted bracket Use mechanical fasteners if adhesive will not adhere Using the emergency disconnect pull disconnect handle downwards and place it in the manual door operated position Use disconnect label for reference Motor will be rotated 90 from its packaged position If motor does not pivot 90 see troubleshooting section in the main installation and owners manual of your idrive opener 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 Securing Door for Spring Winding Tools Needed A WARNING Vice Clamp FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY PLACE VICE Place vice clamps onto both vertical ZA 2 27 CLAMPS ABOVE tracks just above the third roller This is z 3RD ROLLER to prevent the garage door from raising while winding counterbalance springs IMPORTANT DO NOT USE IMPACT GUN TO WIND SPRING S VICE CLAMPS ATTACHED TO INNER RAIL OF TRACK Cable Adjustments COUNTERBALANCE Tools Needed Rotate the cable drum until the set CABLE screw faces directly
5. DoorMaster Bracket DOORMASTER BRACKET DRIVE GEAR ASSEMBLY Tools Needed NOTE When installing a DoorMaster None operator use the center bracket and drive gear supplied with your operator located in DoorMaster package Slide the DoorMaster bracket drive gear assembly onto the TorqueMaster spring tube so that the drive gear center bracket assembly are in the center of the TorqueMaster spring tube NOTE After completing this step TORQUEMASTER TUBE continue with Step 20 on page 22 Tools Needed Power Drill To locate the center bracket mark the con header halfway between the flagangles 1 8 Drill Bit and level the TorqueMaster spring tube CENTER 7 16 Socket Drill 1 8 pilot holes into header for the PUSHING Driver lag screws Fasten the metal bracket to ASSEMBLY the header using 2 1 4 x 1 1 2 lag SCrews NOTE After completing this step continue with Step 29 on page 28 q 2 1 4 X 1 1 2 HEX HEAD LAG SCREWS 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 st Step Plate Tools Needed Make one mark 1 25 mm up from the center of bottom edge of the bottom 7 16 Drill Bit section and another mark 2 3 16 56 mm Power Drill up from the first mark 7 16 Wrench
6. 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 EE STEP PLATE INSIDE from inside using the 8 screws provided 1 4 20 X 5 8 ASSEMBLED 2 8 SCREWS screw i STEP PLATE 02 Install one 8 x 3 4 screw in the bottom CARRIAGE BOLT i step plate hole The screw in the top hole varies with door models Use the screw size shown below for your model door a 8 x 3 4 screw for Model 9100 b 8 x 1 screw Model 9400 9600 Tighten 1 4 20 carriage bolt and nut i Pull Rope Tools Needed A WARNING Power Drill DO NOT INSTALL PULL ROPES 1 8 Drill Bit ON DOORS WITH ELECTRIC OPERATORS CHILDREN MAY BECOME ENTANGLED IN THE PULL ROPE 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 Pa i screw eye Tie the pull rope to the No 6 screw eye and to the bottom bracket Q BOTTOM BRACKET REO PULL ROPE OPTIONAL INSTALLATION 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 on
7. TORQUEMASTER SPRING TUBE CHECK CABLE TENSION COUNTER GEAR COUNTER PRY COUNTER GEAR AND COUNTER COVER FROM END BRACKET USING FLAT TIP SCREWDRIVER 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 TorqueMaster Spring Removal continued Spring tube should be free to rotate in either direction If the counterbalance cable is still taut and the TorqueMaster spring tube is difficult to rotate that is an indication that spring tension still exists on the left hand spring Repeat Steps 1 and 2 for releasing spring tension on the left hand side Step 4 Using a flat tip screwdriver pry the counter gear and counter cover from the right hand end bracket Fig 4 on previous page Discard the counter gear and counter cover On double spring applications repeat for left hand side Tools Needed Recommended tools from page 5 REMOVE TOP LAG SCREW Step 5 Remove the upper 5 16 x 1 5 8 lag screw from the right hand end bracket Fig 5 Attach locking pliers to the upper portion of the end bracket and hold the housing steady while removing the lower 5 16 x 1 5 8 lag screw and 10 x 1 2 phillips head screw from the end bracket Fig 6 Step 6 Holding the right hand
8. to the rib using 2 1 4 20 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 2 1 4 20 x 5 8 self tapping screws every 30 36 inches Approximately 18 self tapping screws per 18 u bar 16 OPERATOR BRACKET 6 1 6 yt INSTALLED IN THE STEP 12 Pee eee 2 1 4 20 X 5 8 SELF TAPPING SCREWS 2 1 4 20 X 11 16 SELF DRILLING SCREWS OPERATOR BRACKET INSTALLED IN THE STEP 12 30 TO 36 U Ban 2 1 4 20 X 5 8 SELF TAPPING 2 1 4 20 X 5 8 SELF SCREWS TAPPING SCREWS 2 1 4 20 X 11 16 SELF DRILLING SCREWS ATTACHING CENTER OF 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 Power Drill 7 16 Socket Driver Vice Clamps Phillips Head Screwdriver ALIGN CENTER OF BOTH TABS WITH CENTER LINE OF TOP SECTION Operator Bracket NOTE Operator bracket must be mounted and secured prior to installing top section OPERATOR IMPORTANT WHEN INSTALLING A PAA RET TROLLEY TYPE OPERATOR ON 9100 9400 AND 9600 SERIES DOORS A WAYNE DALTON TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION ALONG WITH ANY U BAR S
9. jambs NOTE As a safety feature the right hand end bracket cannot be disassembled for service until the spring is completely unwound and the counter cover reads zero After door installation is completed refer to the idrive owner s manual Tools Needed 30 ANGLE BOLTED USING 2 5 16 X 1 5 8 HEX HEAD LAG SCREWS TO CEILING MEMBER AND PARALLEL TO DOOR INSTALLATION BOLT MUST EXTEND INTO P4 THE TRACK TO SERVE AS A ROLLER STOP 0000000000 0000 600009000 cj 31 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 ot Side Lock Tools Needed Install the side lock on the second section of the door Secure the lock to Power Drill 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 approximately 1 8 from the section edge 7 16 Socket Driver 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 9 on page 15 4 1 4 20 X 11 16 SELF DRILLING SCREWS
10. sleeve rotate the M Dalton opener back and forth slightly to help aid alignment i Gaie X Continue sliding the opener onto the TorqueMaster spring tube Align the right hand bearing with the TorqueMaster spring tube and slide the opener completely onto the TorqueMaster spring tube until the TorqueMaster spring tube exits the opener right hand bearing NOTE Do not force the opener onto the bd TorqueMaster spring tube if misalignment occurs dri for TORQUE MASTER Continue sliding the opener to the F p center of the TorqueMaster spring tube PLUG IN MOTOR POWER CORD Plug the motor power cord into the opener 21 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 None Cable Drum Installation Shake the TorqueMaster spring tube gently to extend the winding shafts out about 5 on each side For single spring applications there will be no left hand spring in the TorqueMaster spring tube Lift the TorqueMaster spring tube and rest it on the top of the flagangles Orient TorqueMaster spring tube so that back of opener is flat against header mounting surface NOTE Cable drums are marked right and le
11. 5 8 HEX HEAD LAG SCREW p 16 X 3 4 HEX HEAD 2 3 8 16 X 3 4 1 4 20 X 11 16 SELF DRILLING AS REQUIRED BOLT IF INCLUDED TRUSS HEAD BOLT SCREW AS REQUIRED II Lon AA b 4 1 4 20 X 9 16 LARGE 4 1 4 20 X 5 8 1 4 14 X 5 8 SELF TAPPING 2 12 X 1 2 PHILLIPS 2 10 PHILLIPS HEAD RIBBED TRACK BOLTS CARRIAGE BOLTS SCREW AS REQUIRED HEAD SCREWS HEAD 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 business listings or go to the Find a Dealer section online at www Wayne Dalton com Tools Needed Door Section Identification NOTE This provides an alternative method for identifying your door sections stack position 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 al
12. PREPARING THE OPENING on TS Sos ne page 10 Avoid pushing weather seal too i lt gt SOUND FRAMING MEMBERS tightly against face of door E Page Now lift door and check it s balance 7 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 Adjust if door lifts by itself hard to pull down or if door is difficult to lift easy to pull down Anytime spring adjustments are made you must loosen the lock nuts and retighten both lock nuts afterwards To adjust spring s only add or remove 1 4 turn on the counter at a time Adjust QS both sides equally MS WEATHER IMPORTANT DO NOT ADD OR REMOVE D SEAL MORE THAN 1 SPRING TURN FROM SPECIFIED AMOUNT IF THE DOOR STILL DOES NOT OPERATE EASILY LOWER THE DOOR INTO THE CLOSED POSITION UNWIND SPRING S TO ZERO AND RECHECK THE FOLLOWING ITEMS 3 5 16 3 1 Check the door for level BOLTS amp NUTS P PERMANENTLY ATTACHED 2 Check the TorqueMaster spring tube 2 WEATHER SEAL OR DOOR STOP and flagangles for level and plumb 3 Check the distance between the flagangles must be door width plus 3 3 8 to 3 1 2 4 Check the counterbalance cables for equal tension adjust if necessary 5 Rewind the spring s 6 Make sure door isn t rubbing on
13. UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR AS OUTLINED IN STEP 34 OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY Level the horizontal track assembly and bolt the horizontal angle to the slot in the flagangle usin f 3 8 16 x 3 4 truss head bolt and 8 16 hex nut Repeat for other side Remove the nail that was temporarily normy the top section in place installed in Step 13 IMPORTANT FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION NOTE If an idrive opener will be installed pamon horizontal tracks slightly above evel Adjusting Top Brackets Tools Needed With horizontal tracks installed you can 7 16 Wrench 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 FLAGANGLE 1 4 20 FLANGE HEX NUTS 3 8 16 X 3 4 TRUSS HEAD BOLT TOP SECTION CORRECT 2 1 4 20 FLANGE HEX NUTS INCORRECT 1 4 20 X 9 16 LARGE HEAD mdi RIBBED TRACK BOLTS Pd 3 8 16 HEX NUT HORIZONTAL ANGLE HORIZONTAL TRACK HORIZONTAL TRACK N cx y FF N a TFN T TOP po amp BRA
14. away from the DIM header TorqueMaster spring tube cam Flat Tip peak should be pointing straight up CAM FEN Screwdriver STRAIGHT UP Locking Pliers Beginning with the right side loosen the set screw enough to adjust cable approximately 2 turns Using locking pliers pull on the end of the cable to remove all cable slack Check to ensure the cable is aligned and seated in the first groove of the cable drum Snug the set screw then tighten an additional 1 1 2 turns Cut excess cable SET SCREW 28 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 Bolt Rotation Tools Needed See chart in Step 32 for proper spring tension setting Power Drill Beginning with the right hand side ensure 7 16 Socket the cable is in the first groove of the cable Driver drum Apply light pressure to the canoe clip on counter cover while winding springs Using a power drill high torque gear reduced to 1300 RPM preferred with a 7 16 socket carefully rotate right hand winding bolt clockwise until counter shows 2 3 turns This will keep the counterbalance cable taut while adjusting the left hand side counterbalance cable Adjust left hand counterbalance cable tension refer to Y a Step 30 NOTE Single spr
15. installation and LIT S er DISCONNECT owners manual for drive parts y C i SS CABLE Pliers HOLE IN RIGHT Attach the loose disconnect cable S SO END BRACKET located in opener hardware bag to the IN opener with the S hook Close both ends of the S hook with pliers to lock assembly together Thread the disconnect cable behind the counterbalance cable through the hole in the right hand end bracket remove all slack between opener and right end RIGHT SIDE OF bracket END BRACKET p HOLE IN END BRACKET I Mounting Disconnect m FA Handle Bracket mee nee NOTE See idrive main installation and E Pencil owners manual for idrive parts 3 E Tape measure l m Bis ME Mark a location on the right jamb 6 1 8 Drill Bit feet above the floor to mount the 7 16 Socket disconnect handle bracket Driver E Drill 1 8 pilot holes for the lag screws p Power Drill Align top of the bracket with the mark Fasten bracket to the jamb with 2 1 4 x 1 1 2 lag screws 6ft S 2 1 4 X 1 1 2 LAG SCREWS ie zi DISCONNECT EE Y HANDLE BRACKET 26 Please Do Not Return This Product To The Store Contact your lo
16. 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 Continue 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 center hinge s 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 FROM SAFETY CABLE IF INSTALLED REPEAT FOR OPPOSITE SIDE BOTTOM SECTION DOOR OPEN CAREFULLY REMOVE S HOOK AND COUNTREBALANCE CABLE REPEAT FOR THE OPPOSITE SIDE HORIZONTAL ANGLE TOP BRACKET f HORIZONTAL TRACK local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton co
17. the lag screws Then MOUNTING secure support bracket to the mounting STUDS surface with 2 1 4 x 1 1 2 lag screws INSTALLATION MOUNTING mate BRACKET IMPORTANT TORQUEMASTER SPRING SLOTS TUBE MUST BE LEVEL AFTER SUPPORT BRACKET IS FASTEN TO MOUNTING SURFACE behind dry wall use 1 4 x 2 lag TORQUEMASTER BRACKET SPRING TUBE NOTE If wood mounting surface is 4 SUPPORT Screws Lift and slide the opener over the support bracket aligning the mounting studs with the bracket slots Loosely fasten to mounting studs with the 2 1 4 20 flange nuts 2 1 4 20 FLANGE NUTS NOTE Do not tighten 1 4 20 flange nuts to opener studs at this time Remove the temporary orange label holding the antenna wire Straighten antenna wire and angle it 45 degrees to the right NOTE Do not coil the antenna wire This will reduce the radio signal range TOP SECTION USING A TAPE MEASURE MAINTAIN AN EQUAL MEASUREMENT X TOP OF DOOR TO BOTTOM OF TORQUEMASTER TUBE AT BOTH ENDS AND THE CENTER 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 Attaching Disconnect Cables Tools Needed NOTE See idrive main
18. which the product was purchased Unless the dealer is no longer in business a written claim to the Manufacturer will be the same as if no claim had been made at all At the Manufacturer s option a service representative may inspect the product on site or Buyer may be required to return the product to the Manufacturer at Buyer s expense Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the product with the claimed defect and full access to the location of its installation If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty the Manufacturer will repair or replace the defective product The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer subject to applicable law THE REMEDY WILL COVER ONLY MATERIAL THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES SUCH AS FIELD SERVICE LABOR FOR REMOVAL INSTALLATION PAINTING SHIPPING ETC Any repairs or replacements arranged by Manufacturer will be covered by and subject to the terms conditions limitations and exceptions of this Limited 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
19. wraps are identified as right and left hand To install place the drum wrap over the cable drum and under the idrive disconnect cable right hand side Align the outside flange over the outside edge of the cable drum and push the drum wrap down onto the cable drum Repeat for left hand side NOTE Drum wraps must be installed to prevent cable from becoming tangled IMPORTANT RIGHT AND LEFT HAND ARE ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT Rear Support A WARNING KEEP HORIZONTAL TRACK PARALLEL AND WITHIN 3 4 MAXIMUM OF DOOR EDGE OTHERWISE DOOR COULD FALL RESULTING IN SEVERE INJURY OR 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 or lowering while installing the rear support Using perforated angle 5 16 x 1 5 8 hex head lag screws and 5 16 bolts with DOOR IN THE UP POSI
20. 1 4 20 X 9 16 LARGE HEAD RIBBED Hand tighten the flagangle to the vertical TRACK BOLTS track using 2 1 4 20 x 9 16 large 174 20 head ribbed track bolts or stud plate if FLANGE HEX included and 2 1 4 20 flange hex NUTS nuts Secure the flange nuts after flagangle spacing is complete Step 13 VERITCAL TRACK STUD PLATE HORIZONTAL ANGLE Horizontal Angle KEY SLOT Tools Needed Position the horizontal angle as shown Place tabs of horizontal angle in the key slot of horizontal track Using a hammer tap the horizontal angle towards the curved end of the track until the hole in track and angle are aligned Set tracks aside Hammer HORIZONTAL TRACK NOTE For larger doors a full length horizontal angle may or may not be spot welded to the horizontal track If the horizontal angle is not welded the horizontal angle will be installed as shown HORIZONTAL ANGLE HORIZONTAL NOTE If you have riveted track skip TRACK these step 4 and proceed to step 5 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 Tools Needed None Tools Needed None Installing Q 1 Jamb Brackets Measure the length of the vertical tracks Using the jamb bracket schedu
21. CKET O SLIDE 0 oT 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 Dalton com INSTALLATION 20 TorqueMaster Spring Tube Tools Needed TorqueMaster springs come lubricated and pre assembled inside the TorqueMaster spring tube To install lay the TorqueMaster spring tube on the floor inside garage in front of the door with the labeled end to the left None 18 Tools Needed Center Bracket Bushing NOTE If you are installing the idrive opener on your garage door skip this step and continue with Step 19 NOTE If you are not installing the idrive opener on your garage door you must install the center bracket bushing assembly Follow these instructions for non idrive operated garage doors NOTE If you are installing a DoorMaster opener see optional DoorMaster Bracket installations on page 32 Figure A Being cam shaped the center bracket bushing only fits one way Slide the center bracket assembly towards the center of the TorqueMaster spring tube from the right side as shown NOTE Upon completion of this step continue with Step 20 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dal
22. E SEVERE OR FATAL INJURY Do not release the torsion spring tension unless you are qualified and experienced door technician but have a professional door agency release the tension Step 1 Close the door and place vice clamps to the back legs on both vertical tracks above the third roller 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 SET SCREWS 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 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 ar
23. EL IT 7 16 Socket THE VERTICAL TRACK ON THE SHIMMED Driver SIDE MUST BE RAISED THE HEIGHT OF Tape Measure THE SHIM VERTICAL TRACK Level Position the left hand vertical track ASSEMBLY assembly over the rollers of the bottom LAG section Make sure the counterbalance cable is located between the rollers LOCATIONS 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 1 5 8 lag screws QUICK INSTALL Tighten lag screw securing bottom i R jamb bracket to jamb to maintain 5 8 spacing Hang cable drum over flagangle Repeat for the right hand side v 12R amp 15R FULLY ADJUSTABLE FLAGANGLE 14 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 see page 4 Power Drill 7 16 Socket NOTE Make sure hinges are flipped down Driver when stacking another section on top Place rollers in hinge tubes of the second section lock section With assistance lift second section and guide rollers into the vertical tracks Keep sections aligned and fasten hinges to connect the sections usin
24. ING PLIERS TO HOLD END BRACKET REMOVE 10 PHILLIPS HEAD SCREW HOLD THE END BRACKET STEADY WITH LOCKING PLIERS PRY END BRACKET FROM WINDING SHAFT USING A FLAT TIP SCREW DRIVER AND LOCKING PLIERS SL S REMOVE CABLE DRUM AND WINDING SHAFT DRAPE CABLE ACROSS TOP OF FLAGANGLE LIFT TORQUEMASTER SPRING TUBE OFF FLAGANGLE 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
25. INITIALLY PROVIDED WITH THE DOOR IT IS THEN UNNECESSARY TO FURTHER REINFORCE THE TOP SECTION OF THE ABOVE MODEL WAYNE DALTON OPPOSITE SIDE OF DOOR WHEN ATTACHING A TROLLEY OPERATOR BRACKET TYPE OPERATOR AS LONG AS THE INSTALLATION OF THE OPERATOR IS ACCORDING TO INSTALLATION INSTRUCTIONS AND OWNER S MANUAL AND FORCE SETTINGS ARE ADJUSTED PROPERLY Prior to installing top section locate the LE center of the top section and seat the KE 2 12 X 1 2 operator bracket on male part of the top GEE section For retro fit applications the operator bracket must be aligned with an existing operator and positioned on OPERATOR top section so it bridges the transition X i BRACKET point of the section thickness as shown x N in FIG 1 1 and 1 2 Install 2 12 x 1 2 phillips head screws on the opposite side of operator bracket as shown in FIG 1 3 Clamp operator bracket to u bar if furnished as shown in FIG 1 4 First attach 4 1 4 14 x 5 8 self tapping screws to the operator bracket as Z shown in FIG 1 5 Then attach 2 1 4 gt 14 x 5 8 self tapping screws to the operator bracket as shown in FIG 1 6 1 4 14 X 5 8 SELF TAPPING Remove vice clamps SCREWS SCREWS NOTE If you have a 9100 door 2 of the 1 4 20 x 11 16 self drilling screws used to attach the u bar instead of 2 1 4 14 x 5 8 self tapping screws when attaching operator bracket to u bar as s
26. ME OF INSTALLATION AND MONTHLY THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X 4 BOARD LAID FLAT UNDER THE DOOR FAILURE TO ADJUST OPERATOR IF NECESSARY CAN RESULT IN SEVERE OR FATAL INJURY IF 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 PHOTOELECTRIC EYE SYSTEM IS OBSTRUCTED FAILURE TO MAKE ADJUSTMENTS IF NECESSARY CAN RESULT IN SEVERE OR FATAL INJURY 1 Install operator rail 1 2 to 1 1 2 13 38 mm above high arc of top section of the door 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 12 Attach operator to a suitable mounting surface 2 x 6 lumber minimum FRAMING MEMBERS Attach operator to ceiling using i perforated angle IMPORTANT ANGLE MUST BE ATTACHED TO FRAMING MEMBER S 5 PERFORATED ANGLE 36 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 co
27. NTER GEAR MISSING COUNTER COVER HEX OF THE COUNTER ro CENTER BRACKET BUSHING ASSEMBLY 2 5 16 X 1 5 8 HEX HEAD LAG 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 business listings or go to the Find a Dealer section online at www Wayne Dalton com Positioning Support Bracket Tools Needed NOTE See idrive main installation and 45ANGLE 7 ANTENNA zi MOUNTING owners manual for idrive parts amp 4 WIRE E SURFACE Power Drill 1 8 Drill Bit NOTE idrive must be installed on a solid mounting surface aune 7 16 Socket bd Driver Locate the mounting surface The mounting surface is a vertical board running directly above the center of the A p door Remove 2 1 4 20 flange nuts TORQUEMASTER SPRING TUBE from bottom of opener m SUPPORT BRACKET NOTE Do not discard flange nuts Uf X 1 1 2 LAG Place the support bracket underneath SCREWS opener to the right side of motor centered on mounting surface Using a TOP OF Quer 1 4 20 tape measure level the bottom of the y FLANGE NUTS TorqueMaster spring tube to the top of the door section with the idrive resting on the support bracket Once TorqueMaster spring tube is level drill 1 8 pilot holes for
28. PENING 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 counterbalance 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 spring counterbalance systems 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 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 A WARNING TORSION ASSE Approved FAILURE TO USE APPROVED APPROVED WINDING BAR Winding Bars WINDING BARS CAN CAUSE SPRING ENERGY TO BE RELEASED 3 8 Wrench SUDDENLY RESULTING IN SEVERE OR FATAL INJURY Vice Clamp amp WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED Recommended BEFORE REMOVING ANY tools from HARDWARE A POWERFUL page 5 SPRING RELEASING IT S ENERGY SUDDENLY CAN CAUS
29. TION af zs S 7 2 ui 3 4 7 I 3 DOOR EDGE I li IN rud NI ll O 2 SL nop E UE l 1 1 V 1 I 1 HORIZONTAL j I TRACK j I YB E d Tiet VICE CLAMPS VERTICAL 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 Rear Support Continued P P _ SOUND FRAMING MEMBERS lt nuts may not be supplied fabricate i VEM Be we 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 30 ANGLE BOLTED NOTE If rear supports are to be installed M USING 2 5 16 X 1 5 8 over drywall use 5 16 x 2 hex head lag RU HEX HEAD LAG SCREWS SCrews x TO CEILING MEMBER AND NOTE If an idrive opener will be Q PARALLEL TO DOOR installed position horizontal tracks one hole above level when securing it to rear supports HORIZONTAL TRACK BOLT MUST EXTEND INTO Adjust weather seal if necessary THE TRACK TO SERVE AS Permanently attach the weather seal to A ROLLER STOP both door jambs and header Temporarily attached in
30. To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com NOTE DEPENDING ON THE DOOR MODEL SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT Package Contents NECESSARY REAR SUPPORTS MAY OR MAY NOT BE INCLUDED WITH YOUR DOOR DOOR SECTIONS AS REQUIRED 2 TOP BRACKET SLIDE 1 TORQUEMASTER SPRING TUBE a 2 HORIZONTAL TRACK RH LH 2 FULLY ADJUSTABLE RH LH 2 QUICK INSTALL RH LH FLAGANGLE AS REQUIRED FLAGANGLE AS REQUIRED li NU N 7 i NV J NU 2 nhe S i 2 HORIZONTAL ANGLE RIGHT AND LEFT CABLE ASYMMETRICAL U BAR U BAR IDRIVE OPERATOR 21 15 16 OR 80 DRUM ASSEMBLIES IF INCLUDED IF INCLUDED SOLD SEPARATELY AS REQUIRED l RIGHT amp LEFT Q I JAMB BRACKETS 1 OPERATOR BRACKET 2 TOP BRACKET BASE WEATHER SEAL amp NAILS 2 VERTICAL DRUM ir AS REQUIRED p IF INCLUDED TRACK RH LH RIGHT amp LEFT 36 TOOTH WORM GEAR bri COVERS COUNTER GEAR ROLLERS 1 CENTER BRACKET END BRACKETS AS REQUIRED AS REQUIRED AS REQUIRED AS REQUIRED ASSEMBLY O E MANUAL STUD PLATE LUBRICATING OIL PULLROPE 1 LOOSE WINDING SHAFT 1 3 8 16 NYLOCK 1 4 20 FLANGED HEX IF INCLUDED AS REQUIRED IF INCLUDED SINGLE SPRING ONLY NUT IF INCLUDED NUT AS REQUIRED gt e 2 3 8 16 HEX NUT 5 16 X 1
31. Wayne Dalton 9100 9400 AND 9600 TorqueMaster Single and Double Spring Installation Instructions and Owner s Manual IMPORTANT NOTICE Read these instructions carefully before attempting installation If in question about any of the proce dures do not perform the work Instead have a www Wayne Dalton com qualified door agency do the installation or repairs Wayne Dalton a Division of Overhead Door Corporation P O Box 67 Mt Hope OH 44660 Copyright 2010 Wayne Dalton a Division of Overhead Door Corporation Part No 302868 REV7 02 25 2010 Table of Contents ImpontantSatetynstHetol see nee 2 Package Coritents ssec e eruat E e TIE 3 DoonSectionildentificationeeseee eee eee 4 loolsiRequitediswawovavascns cnn rat T S awn E Tate 5 Precinstallationeecentsss cere eee re ree ees 5 10 Removing The Old Door 5 9 Dreparinciit e Openitidgpee um 10 Installation eese tee ETE 11 31 Optionalllnstallations a a rM 32 36 Sidelock e ae ee 32 Doormaste Bracket eaei e 32 Stepiplato er eere 83 PURO po e a e e E EE DE 33 Trolley Instructions For Standard Lift 34 Trolley Instructions For Low Headroom 35 Mrolley Operatoheecss etree eres 36 Maintenance eee 37 38 Ee I r eere RET S 37 Daintngilnst ctionseeeee eee 37 38 Warranty 39 pyealenirocatomibformationeese serene eee 40 Definition of key words used in this ma
32. cal 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 Phillips head screwdriver Wire cutters Attaching Disconnect Handle NOTE See idrive main installation and owners manual for idrive parts UPPER POSITION NOTE Bring motor to the down position 6 20 X 1 2 by pulling the disconnect cable insure SCREW opener disconnect teeth are engaged before installing disconnect handle Emergency Disconnect Start the 6 20 x 1 2 screw into the Cray Mat disconnect handle Thread the rur disconnect cable through the top of the disconnect handle bracket and then the disconnect handle HANDLE Don USe emerge Locate the disconnect handle in full cera upper position of disconnect handle bracket Remove all disconnect cable slack DISCONNECT EMERGENCY DISCONNECT between the opener and the top of the LABEL disconnect handle bracket Tighten 6 20 x 1 2 screw into the disconnect handle until snug and then tighten screw an additional 1 to 1 1 2 turns to secure disconnect cable to the SEDE disconnect handle Trim off excess cable BRACKET from bottom of the disconnect handle MANUAL OPERATED POSITION MOTOR OPERATED POSITION CAUTION PULL CABLE ONLY TAUT ENOUGH TO REMOVE THE CABLE SLACK PULLING THE CABLE MORE COULD CAUSE OPENER TO DISCONNECT FROM THE TORQUEMASTER SPRING TUBE
33. d 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 MAINTENANCE 37 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 Painting Continued NOTES 1 Repainting of finish painted steel doors cannot be warranted as this condition is totally beyond the door manufacturer s control 2 Consult a professional coatings contractor if in doubt about any of the above directions 3 Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers Pay particular attention to acceptable weather and temperature conditions in which to paint 38 Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings
34. e vertical track installation by securing the center jamb bracket and tightening the other lag screws Repeat for other side Hammer IMPORTANT THE DIMENSION BETWEEN THE FLAGANGLES MUST BE DOOR WIDTH PLUS 3 3 8 86 MM TO 3 1 2 89 MM FOR SMOOTH SAFE DOOR OPERATION Attaching Quick Install Flagangle to Horizontal Track NOTE If you have fully aoe flagangle skip this step and complete Step 15 To install horizontal track place the curved end over the top roller Align key slot of the Tools Needed 9 16 Socket Ratchet Wrench horizontal track un ins quick instal tab of the flagangle Push curved portion o 9 16 Wrench horizontal track down to lock in place Level A WARNING DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT REAR AS OUTLINED IN STEP 34 OR DOOR COULD FALL FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY Level the horizontal track assembly and bolt the horizontal angle to the slot in the flagangle usin 3 8 16 x 3 4 truss head bolt and f 8 16 hex nut Repeat for other side Remove the nail that was temporarily d the top section in place installed in Step 13 IMPORTANT FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD CAUSE PERMANENT DAMAGE TO TOP SECTION NOTE If an idrive opener will be installed osition horizontal tracks slightly above level OTE After completing this step continue with Step 16
35. ea 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 business listings or go to the Find a Dealer section online at www Wayne Dalton com TorqueMaster Spring Removal A TorqueMaster spring system can be identified by the end brackets For single spring applications the right hand end Recommended bracket will always have a drive gear tools from counter gear counter cover and a winding page 5 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 Tools Needed 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 1 4 turn using a 7 16 wrench and continue with Step 2 If you have a gray counter cover Loosen the lock nut 1 4 turn using a 7 16 wrench and continue with Step 2 Step 2 Using an electric drill High torque gear reduced to 1300 rpm preferr
36. ed 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 listed number of turns 6 0 Door Height 14 turns 6 3 Door Height 14 1 2 turns 6 5 Door Height 15 turns 6 6 Door Height 15 turns 6 8 Door Height 15 1 2 turns 6 9 Door Height 15 1 2 turns 7 0 Door Height 16 turns 7 3 Door Height 16 1 2 turns 7 6 Door Height 17 turns 7 9 Door Height 17 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 NUT 1 4 TURN GEAR COVER j E N RIGHT HAND US A 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 RIGHT HAND CABLE DRUM
37. end bracket steady with locking pliers carefully pry the end bracket and drive gear off the winding shaft using a flat tip screwdriver Fig 7 CAUTION THE WINDING SHAFT MAY ROTATE WHEN REMOVING THE END BRACKET AND DRIVE GEAR Step 7 Repeat Step 4 for the left hand side Holding the left hand end bracket steady with locking pliers carefully pry the end bracket off the winding shaft using a flat tip screwdriver Fig 7 REMOVE SCREW Step 8 Remove the two 2 lag bolts attaching the center bracket assembly to the header board Fig 8 Step 9 Lift the right hand side of the TorqueMaster spring tube and slide the cable drum off Realign the groove in the winding shaft with the radial notch in the flagangle and drape the counterbalance cable with drum over the flagangle Lift the left hand side of the TorqueMaster spring tube and slide the cable drum and winding shaft off Fig 9 Drape the counterbalance cable with drum over the flagangle Lift the TorqueMaster spring assembly off the flagangles and out of the doorway Unhook the counterbalance cables from the bottom brackets and remove all parts from the work area NOTE The cable drums may be difficult to remove If so twist the cable drum to aid in removal NOTE Continue with P4 on page 9 after completing this step CENTER BRACKET ASSEMBLY Fig 8 BOTTOM LAG _ gt amp 2 5 16 X 1 5 8 HEX HEAD LAG SCREWS USE LOCK
38. ess listings or go to the Find a Dealer section online at www Wayne Dalton com Trolley Installation for TYPICAL 1 2 1 Low Headroom ABOVE HIGH ARC TORQUEMASTER RE HIGH ARC COUNTERBALANCE Determine center line of door Mark vertical line at this TOP Do LINE y point on the header wall Raise the door slightly until the SECTION HEADROOM i top section reaches the highest point of travel high arc TRACK i Using a level mark this high arc point of travel on the header ee i i l wall intersecting the vertical center line as shown in FIG t 3 1 through 3 2 Hold the wall bracket s bottom edge to the E appropriate 1 2 1 room permitting above of the high Rin I CENTER LINE arc line and centered on the vertical line as shown in FIG Er HEADER 3 2 Spot the wall brackets mounting holes on the header allo wall and then refer to your garage door operator manual for pre drilling and securing the wall bracket to header Using the FIG 3 2 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 CURVED NOTE Depending on your setup you may or may not have to cut straight arm to accomplish trolley setting
39. even with door section UB 6 BOTTOM UB 6 M UB 6 M TRA UB 7 TOP ale rro QUB 6 BOTTOM MIDDLE UB 5 BO UB 5 BO UB 6 TOP UB 7 TOP LEFT HAND TORQUEMASTER COUNTERBALANCE DRUM BOTTOM SECTION gt gt COUNTERBALANCE CABLE QUICK INSTALL FEATURE 1ST SET HOLES 1 END HINGE SECTION HINGETUBE BOTTOM SECTION BOTTOM BRACKET 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 INSTALLATION 6 Bottom Section Tools Needed Before installing the bottom section the weather seal may not be included must be installed see PREPARING THE OPENING on page 10 Level Center the bottom section in the door opening Level section using wooden shims if necessary under the bottom section EATHER SEAL DOOR OPENING LEVEL WOODEN SHIMS IF NECESSARY F Vertical Track Ma FLAGANGLE BOTTOM SECTION 5 o Tools Needed IMPORTANT THE TOPS OF THE 3 16 Drill Bit VERTICAL TRACKS MUST BE LEVEL 25 16 X 1 5 8 Power Drill FROM SIDE TO SIDE IF THE BOTTOM LAG SCREWS SECTION WAS SHIMMED TO LEV
40. ft hand Cable drums and TorqueMaster spring tube are cam shaped to fit together only one way To install the cable drum slide the correct cable drum over the winding shaft until the cable drum seats against the TorqueMaster spring tube The winding shaft must extend past the cable drum far enough to expose the splines and the groove Align the winding shaft groove with the round notch in the flagangle For Double Spring Applications Repeat for opposite side For Single Spring Applications Insert the loose winding shaft into the left hand cable drum prior to sliding the cable drum over the TorqueMaster spring tube NOTE On single spring applications take care in handling the loose winding shaft left side so that it does not slide back into the TorqueMaster spring tube WINDING S S TORQUEMASTER SPRING TUBE GROOVE SHAFT RIGHT HAND CABLE DRUM FLAGANGLE TORQUEMASTER SPRING TUBE FLAGANGLE TORQUEMASTER SPRING TUBE GROOVE COUNTERBALANCE WINDING SHAFT GROOVE ROUND NOTCH WINDING SHAFT TORQUEMASTER SPRING TUBE LOOSE WINDING 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 Drive Gear Installation WINDING uw SHAFT f OIL lubricate entire circumfere
41. g 1 4 14 x 5 8 self tapping screws Repeat for other section s except top section IMPORTANT PUSH amp HOLD THE HINGE Z LEAF AGAINST SECTION WHILE SECURING 1 14 X 5 8 SELF TAPPING WITH 1 4 14 X 5 8 SELF TAPPING Dq E SCREWS SCREWS END HINGES HAVE 2 SCREWS e E crc AND INTERMEDIATE HINGES HAVE 3 SCREWS INSTALLATION 1 4 44X 5 8 oa j NOTE Install lock at this time sold pum separately see instructions in OPTIONAL Fu SELF ees END HINGES LEFT HAND SHOWN RIGHT SOELOCK INSTALLATION on page 32 NTEFNEDITE HNES 1ST SET gt o TOP SECTION 9 Top Brackets 2ND SET ra 4 1 4 14 x 5 8 SELF TAPPING Tools Needed To install the L shaped top brackets SCREWS align the top holes in the top bracket base with the second set of holes in the 7 1 6 Socket endcap Driver Power Drill TOP BRACKET BASE Fasten using 4 1 4 14 x 5 8 self tapping screws Secure the top bracket 2 1 4 20 x 5 8 slide to the bracket base loosely using ARRIAGE BOLTS 2 1 4 20 x 5 8 carriage bolts and 2 1 4 20 flanged hex nuts The TOP BRACKET SLIDE bracket will be tightened and adjusted e 2 1 4 20 in Step 16 Insert rollers into top bracket FLANGED HEX slide Repeat for other side TOP SECTION
42. garage to allow the door to open fully 10 SUITABLE MOUNTING SURFACE 2 X 6 HEADER BOARD LUMBER MINIMUM 2 X 6 LUMBER Oa PREFERRED A LEVEL HEADER HEIGHT PLUMB JAMBS HEADROOM HEADER BACKROOM WEATHER SEAL p WEATHER SEAL A HEADROOM REQUIREMENT TRACK TYPE TorqueMaster 15 Radius track 11 3 4 299 mm 12 Radius track 10 1 2 267 mm 6 LHR Kitt 6 152 mm BACKROOM REQUIREMENT MANUAL MOTOR DOOR HEIGHT TRACK LIFT OPERATED ig pn Fati j 98 120 6 5 6 6 7 0 12 15 Radius 2489 mm 3048 mm n d i 110 bol 7 6 8 0 12 15 Radius 2794 mm 3353 mm 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 PT2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS END BRACKETS JAMB BRACKETS OPERATOR MOUNTING SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER PRESERVATIVE TREATED STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN TREATED LUMBER NOTE It is rec
43. hown in FIG 1 6 NOTE When attaching operator bracket to top section with u bar apply additional pressure to thread into the u bar NOTE See FlG 1 7 for installing operator bracket on top section without u bars PHILLIPS HEAD MALE PART OF TOP SECTION OPERATOR BRACKET SECTION FIG 1 2 OPERATOR BRACKET VICE CLAMP NOTE NOT REQUIRED FOR J STRUTS 2 1 4 14 X 5 8 SELF TAPPING SCREWS OPERATOR 2 SELF DRILLING SCREWS NR z gt p x 6 1 4 14 X 5 8 SELF TAPPING SCREWS OPERATOR BRACKET 17 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 18 1 3 Top Section Tools Needed 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 hold tight against section and fasten center hinges first and end hinges last Refer to Step 8 When installing a door with a TorqueMaster 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 Flagangles must be parallel to the door sections Now complete th
44. ing applications require A WARN ING no spring winding on left hand side but PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE need cable tension adjusted 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 number of turns If cable tension is DIRECTION AND COULD RESULT IN SEVERE OR FATAL NOTE Ensure counterbalance cable tension is equal for both sides prior to fully winding spring s to appropriate unequal refer to Step 30 Setting Spring Tension NOTE Apply light pressure to the canoe clip on the counter cover while winding spring s See the Spring Turn chart Tools Needed CANOE CLIP WRENCH Power Drill For SINGLE SPRING applications return to the right hand GET T Ww 7 16 Socket side and carefully rotate the winding bolt head clockwise windows the recommended number of spring turns is 15 Driver until the counter shows the correct number of turns for your door For DOUBLE SPRING applications remain on the left hand side and carefully rotate the winding bolt head clockwise until the counter shows the correct number of turns for your door Then return to the right hand side and wind the right hand spring to the required number of turns IMPORTANT DO NOT OVERWIND After spring is wound hold the lock nut in back of end bracket stationa
45. le determine the placement of the jamb brackets for your door height and track type To install the jamb brackets align the twistlock tab on the quick install jamb bracket with the quick install feature in the track and turn the bracket perpendicular to the track so the mounting flange is toward the back flat leg of the track LEFT SIDE SHOWN JAMB BRACKET SCHEDULE TWISTLOCK TAB pooR 1ST SET 2ND SET JAMBBKT POSITION JAMBBKT POSITION JAMBBKT POSITION Ms ae QUB 5 MIDDLE a e soro NOT APPLICABLE al Lo 6 5 69 TRACK QUB 3 BOTTOM NOT APPLICABLE 1753 QI JAMB BRACKET 2ND SET HOLES 79 al Eso QIJB 3 MIDDLE B 7 MIDDLE QIJB OTTOM QIJB 8 TOP IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT NOTE For door section identification see page 4 TorqueMaster counterbalance drums are marked right and left hand Uncoil the counterbalance cables and make sure you place the right hand cable loop on the right hand milford pin and place the left hand cable loop on the left hand milford pin Insert a roller into bottom bracket of the bottom section and insert another roller at 1 end hinge at the top of the bottom section Repeat for other side NOTE Verify astragal bottom seal is aligned with door section If there is more than 1 2 excess astragal on either side trim astragal
46. ligations 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 39 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 2 507 590 2 530 701 2 530 74 2 2 532 824 Other US and Foreign Patents pending Please Do Not Return This Product To The Store Contact your local Wayne Dalton dealer To find your local Wayne Dalton dealer refer to your local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com Thank you for your purchase 40
47. line at www Wayne Dalton com DETERMINE THE WAYNE DALTON Trolley Installation for TRACK RADIUS BEING USED Standard Lift HORIZONTAL Measure the curved ends of the horizontal track to determine TRACK if you have a 12 or 15 radius horizontal track as shown in FIG 2 1 Determine center line of door Mark vertical line 12 OR 15 at this point on the header wall Raise the door slightly until l 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 FIG 2 1 2 2 through 2 3 Hold the wall bracket s bottom edge to the appropriate 1 2 1 room permitting above of the high TYPICAL 1 2 1 ABOVE HIGH ARC arc line and centered on the vertical line as shown in FIG HIGH ARC TORQUEMASTER 2 3 Spot the wall brackets mounting holes on the header COUNTERBALANCE wall and then refer to your garage door operator manual for B STRAIGHT 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 1 VERTICAL trolley to operator bracket PSECU eur Sm I i NOTE Refer to your operator manual for specific details on STEP 12 x HEADER i 7 ACCOMPLISH how to assembly the curved and straight arm as shown in o El o ma y rd FIG 2 4 through FIG 2 5
48. ll 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 Warranty is extended only to the person who purchased the product and continues to own the premises where the door is installed as his her primary residence Buyer This Limited Warranty does not apply to residences other than primary or to commercial or industrial installations or to installations on rental property even when used by a tenant as a residence This Limited Warranty is not transferable to any other person even when the premises is sold nor does it extend benefits to any other person As a resu
49. lt 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 DEFINED BY THE MAGNUSON MOSS ACT NO WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE WILL EXTEND BEYOND THE TIME PERIOD SET FORTH IN UNDER SCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY ABOVE 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
50. m 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 0 596 phosphate is not recommended for use in general cleaning of garage doors NOTE Be sure to clean behind weather stripping on both sides and top of door CAUTION NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH GLASS CLEANING INSTRUCTIONS Clean with a mild detergent solution same as above and a soft cloth After cleaning rinse thoroughly ACRYLIC CLEANING INSTRUCTIONS Clean acrylic glazing with nonabrasive soap or detergent and plenty of water Use your bare hands to feel and dislodge any caked on particles A soft grit free cloth sponge or chamois may be used to wipe the surface Do not use hard
51. m PRE INSTALLATION Preparing the Opening FAILURE TO SECURELY e WARNING ATTACH A SUITABLE MOUNTING PAD TO STRUCTURALLY SOUND FRAMING COULD CAUSE SPRINGS TO VIOLENTLY PULL MOUNTING PAD FROM WALL RESULTING IN SEVERE OR FATAL INJURY If you just removed your existing door or you are installing a new door complete all steps in PREPARING THE OPENING Tools Needed Recommended tools from page 5 For detailed technical information regarding the opening preparation refer to the DASMA Technical Data Sheet TDS 161 Connecting Garage Door Jambs to Building Framing located at www dasma com The inside of your garage door opening should be framed with wood jambs and header 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 IMPORTANT CLOSELY INSPECT JAMBS HEADER AND MOUNTING SURFACE ANY WOOD FOUND NOT TO BE SOUND MUST BE REPLACED The jambs and header must be securely fastened to sound framing members Do not place jambs and header over drywall paneling etc Heads of fasteners must be flush or below jamb and header surface so they do not interfere with installation or operation of new door TorqueMaster coun
52. nce of the 36 tooth worm gear with the lubricating oil 36 Tooth Worm provided Slide the 36th worm gear Gear onto the winding shaft splines until it touches the flagangle Lubricating Oil NOTE On single spring applications FLAGANGLE gt no drive gear is required on the left side NOTE If additional lubricating oil is needed use Dura Lube Engine Oil Treatment 36 TOOTH WINDING SHAFT INSTALLATION End Brackets END BRACKET WARNING Tools Needed IMPORTANT WARNING TAGS MUST BE TAG SECURELY ATTACHED TO BOTH END BRACKETS Slide the right hand end bracket over the drive gear and fasten to the flagangle using a 10 self tapping Phillips Head screw Drill 3 16 pilot holes into jamb Screwdriver for the lag screws Secure end bracket and the flagangle to the jamb using 2 5 16 x 1 5 8 lag screws Repeat for left hand side 2 5 16 X 1 5 8 Q LAG SCREWS Power Drill 3 16 Drill Bit 7 16 Socket Driver 10 PHILLIPS HEAD SCREW 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 24 Tools Needed None 24 Tools Needed Counter Installation Install the right side counter gear with the missing tooth toward the outside and away from the end bracket Press
53. nual A 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 OS ENT 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 10 11 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 over 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 finger
54. ommended that 5 16 x 1 5 8 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 QUICK INSTALL TAB UNLOCKED QUICK INSTALL TAB LOCKED Attaching Quick Install Flag Angle to Vertical Track Tools Needed NOTE If you have fully adjustable None flagangle skip this step and complete Step 2 Place the lower quick install tab of the flagangle in the quick install feature of FLAGANGLE the vertical track Give the flagangle 1 4 FLAGANGLE e turn to lock in place Repeat for other side NOTE After completing this step continue with Step 3 VERTICAL TRACK TRACK LEFT HAND TRACK AND FLAGANGLE RIGHT HAND TRACK AND FLAGANGLE 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 Attaching Fully Adjustable FULLY ADJUSTABLE FLAGANGLE Flagangle to Vertical Track Tools Needed NOTE If quick install flagangle was installed in Step 1 skip this step and continue with Step 3 If not complete this step None
55. 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 Manufacturer warrants the sections of the door which is described at the top of this page for as long as you own the door against i The door becoming inoperable due to rust through of the steel skin from the core of the door section due to cracking splitting or other deterioration of the steel skin or due to structural failure caused by separation or degradation of the foam insulation ii Peeling of the original paint on the door as a result of a defect in the original paint or in the application of the original paint coating in cases where the door sections and the original paint a have not been subjected to adverse atmospheric conditions or contaminates such as salt water or other marine environment or to toxic or abrasive substances including those in the air b have been maintained in compliance with Manufacturer s recommendations and c have not been subject to physical abrasion impacted by a hard object or punctured including without limitation paint rub occurring in metal to metal contact and movement The Manufacturer warrants the garage door hardware except springs and the tracks of the above described door for as long as you own the door against defects in material and workmanship subject to a
56. 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 forming Sand the exposed area lightly and paint with a high quality metal primer specifically intended for galvanized surfaces to protect the area from corrosion Allow for drying time on primer can label before applying topcoat The surface of the factory applied finish that is being painted must not be too smooth or the paint will not adhere to it It is advisable to test in an inconspicuous area to evaluate adhesion If poor adhesion is observed surface preparation for painting the factory applie
57. 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 exclusion 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 ob
58. ry on the right hand side with a 7 16 wrench while rotating the winding bolt clockwise until snug Tightening of the lock nut prevents spring from unwinding Repeat for opposite side for double spring TorqueMaster systems IMPORTANT CAUTIOUSLY REMOVE VICE CLAMPS FROM VERTICAL TRACKS ADJUSTMENTS TO THE RECOMMENDED NUMBER OF TURNS MAY BE REQUIRED AFTER REAR SUPPORT ASSEMBLY IS COMPLETE STEP 34 CHECK DOOR BALANCE 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 UNBALANCED DOOR SUCH AS THIS CAN CAUSE IDRIVE OPERATION PROBLEMS 7 16 Wrench 13 1 2 ep wo ep oa 14 1 2 14 15 15 1 ce 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 RECOMMENDED SPRING TURNS idrive Operated Manually Operated Door Door Height Doors 11 11 and idrive Operated Wide or Less Doors 12 Wide or Greater pg 9 9 e ow ose o eo ww e 29 INSTALLATION Tools Needed None Tools Needed Ratchet Wrench 1 2 Socket 1 2 Wrench 2 Vice Clamps Tape Measure Level Hammer 30 Drum Wrap Installation Drum
59. s as shown in FIG 3 3 through FIG 3 4 Ls _ CUT STRAIGHT Attach door arm to trolley and align the appropriate door arm nun hole with the hole in the door operator bracket Insert 1 hex TROLLEY head bolt through hole of operator bracket and door arm SETTING Install 1 LOCKING hex nut and just tighten until snug LOCKING A WARNING n FAILURE TO USE LOCKING NUT CAN RESULT IN ARM RE LEASING AND POSSIBLE RESULTING IN PROPERTY DAMAGE AED AND OR PERSONAL INJURY SS 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 OPTIONAL INSTALLATION LINEAR LIFTMASTER SEARS GENIE OPERATORS REQUIRE STRAIGHT ARM 1 5 16 18 x 1 hex bolt and 1 5 16 18 LOCKING hex SHOWN nut as shown in FIG 3 5 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 quavTUM CLAssic CURVED STRAIGHT RAIGHT LIFTMASTER CURVED Gs sen ex smon mess RAIGHT 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 XE Trolley Operator s me Vi OPERATOR RAIL SUITABLE MOUNTING AP Tots ecce PATE EN OPERATOR MUST BE TESTED AT TI
60. s or hands into open section joints when closing a door Use lift handles gripping points when operating door manually 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 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
61. so be used in conjunction with identifying each sections The BOTTOM SECTION can be identified by a 1 end hinge the factory attached bottom astragal or by the bottom bracket warning labels on each end stile The LOCK SECTION can be identified by a 2 end hinge Some sections may have a yellow and black warning label on the right side of the section The INTERMEDIATE SECTION can be identified by a 3 end hinge Some sections may have a warning label attached to either the right or left of the section NOTE 4 End hinges are used on the fourth section of 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 WARNING LABEL TOP SECTION WARNING LABEL INTERMEDIATE SECTION 2 V WARNING LABEL E YELLOW AND BLACK _ LOCK SECTION i2 BOTTOM BRACKET WARNING LABELS BOTTOM SECTION ASTRAGAL SECTION SIDE VIEW 1 1 8 13 8 2 END HINGE HINGE INT USED ONLY ON FIVE SECTIONS BOTTOM BRACKET A a ASTRAGAL Please Do Not Return This Prod
62. terbalance systems 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 The mounting surface must be securely attached to block or concrete wall with four 4 3 8 masonry anchors or four 4 5 16 x 4 lag screws for a wood structure 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 Fit weather seal may not be included to fit the jambs and header Align the edge of the weather seals an 1 8 to 1 4 inside the edge of the opening Temporarily nail the weather seal to the jambs to keep the bottom section from falling out of the opening during installation Space nails approximately 12 apart NOTE Do not permanently attach weather seal to the jambs at this time Permanent installation will be done in Step 34 HEADROOM REQUIREMENT Headroom is defined as the space needed above the top of the door for tracks springs etc to allow the door to open properly If the door is to be motor operated 2 1 2 64 mm of additional headroom is required NOTE 6 LHR Conversion Kit is available for 12 Radius only Contact your local Wayne Dalton dealer BACKROOM REQUIREMENT Backroom is defined as the distance needed from the opening back into the
63. the counter gear onto the end bracket until snaps engage Select the right hand counter cover and align the hex of the counter cam with the end of the winding shaft Also align the O on the counter cover with the raised rib on the end bracket Press the counter cover against the counter gear until it locks into place RAISED RIB Repeat for left hand side for double spring applications NOTE No 36 tooth worm gear counter gear or counter cover is required on left hand side for single spring applications Only an end bracket is needed IMPORTANT AT THIS TIME DO NOT WIND COUNTERBALANCE SPRINGS Securing Center Bracket Assembly NOTE If you are installing the idrive Opener on your garage door skip this step and continue with Step 25 NOTE If you are not installing the idrive opener on your garage door you must install the center bracket bushing assembly Follow these instructions for non idrive operated garage doors NOTE If you are installing a DoorMaster opener see optional DoorMaster Bracket installations on page 32 Figure B To locate the center bracket mark the header halfway between the flagangles and level the TorqueMaster spring tube Drill 1 8 pilot holes into header for the lag screws Fasten the metal bracket to the header using 2 5 16 X 1 5 8 lag screws NOTE Upon completion of this step con tinue with Step 29 WINDING SHAFT INSIDE END BRACKET COU
64. ton dealer refer to your TORQUEMASTER SPRING TUBE N LABELED END CENTER BRACKET ASSEMBLY TORQUEMASTER SPRING TUBE TORQUEMASTER SPRING TUBE CENTER BRACKET BUSHING local yellow pages business listings or go to the Find a Dealer section online at www Wayne Dalton com 1 9 idrive Installation Tools Needed NOTE See idrive main installation and owners manual for idrive parts IMPORTANT RIGHT AND LEFT HAND pat IS ALWAYS DETERMINED FROM INSIDE LEFT HAND SIDE THE GARAGE LOOKING OUT TORQUEMASTER SPRING TUBE AND BEARING PROFILES ALIGNED With the TorqueMaster spring tube on the floor inside garage in front of the door with the labeled end to the left Look into the opener s left side to nsure the left han ring and the Steere eee J OF TORQUEMASTER internal black sleeve are aligned with SPRING TUBE the TorqueMaster spring tube profile IMPORTANT HOLD OPENER BY THE MAIN BODY DO NOT HOLD BY THE MOTOR NOTE Opener will not slide over a torque tube label Attempting to slide opener over the left end of the TorqueMaster spring tube can damage the internal electronics INSTALLATION RIGHT HAND SIDE 3 TORQUEMASTER Once aligned slide the opener onto the P Mg TUN ed AND right hand end of the TorqueMaster eae NU BEARING PROFILES spring tube As the right end of the W 0 7 Ww ALIGNED TorqueMaster spring tube enters the i internal black
65. uct 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 Required sme E E eE D w S POWER DRILL RATCHET WRENCH PLIERS WIRE CUTTERS TAPE MEASURE 1 8 3 16 DRILL BITS A Fa x NN WR RY NO NERDY PHILLIPS HEAD SCREWDRIVER FLAT TIP SCREWDRIVER PENCIL NEEDLE NOSE PLIERS GLOVES o 7 16 1 2 9 16 7 16 SOCKET DRIVER 3 8 7 16 1 2 9 16 SAFETY GLASSES SOCKETS WRENCHES f M EWA STEP LADDER HAMMER VICE GRIPS VICE CLAMPS 2 SAW HORSES 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 O

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