Wayne Dalton 9400 Users Manual

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TorqueMaster® Plus - Single and Double Spring

Installation Instructions and Owner’s Manual

9100, 9400, AND 9600

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

qualified door agency do the installation or repairs.

©Copyright 2012 Wayne-Dalton, a Division of Overhead Door Corporation Part No. 327684 REV4 03/01/2012

Wayne-Dalton, a Division of

Overhead Door Corporation

P.O. Box 67, Mt. Hope, OH 44660

www.Wayne-Dalton.com

2

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

Definition of key words used in this manual:

INDICATES A POTENTIALLY HAZARDOUS

SITUATION WHICH, IF NOT AVOIDED, COULD

RESULT IN SEVERE OR FATAL INJURY.

CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT

FROM FAILURE TO FOLLOW INSTRUCTIONS.

IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER

DOOR OPERATION.

NOTE: Information assuring proper installation of the door.

READ THESE

INSTRUCTIONS CAREFULLY BEFORE

ATTEMPTING INSTALLATION. IF

IN QUESTION ABOUT ANY OF THE

PROCEDURES, DO NOT PERFORM THE

WORK. INSTEAD, HAVE A QUALIFIED

DOOR AGENCY DO THE INSTALLATION

OR REPAIRS.

1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2. Wear protective gloves during installation to avoid possible

cuts from sharp metal edges.

3. It is always recommended to wear eye protection when using

tools, otherwise eye injury could result.

4. Avoid installing your new door on windy days. Door could

fall during the installation causing severe or fatal injury.

5. Doors 12’-0” wide and over should be installed by two

persons, to avoid possible injury.

6. Operate door ONLY when it is properly adjusted and free from

obstructions.

7. If a door becomes hard to operate, inoperative or is damaged,

immediately have necessary adjustments and/or repairs

made by a trained door system technician using proper tools

and instructions.

8. DO NOT stand or walk under a moving door, or permit

anybody to stand or walk under an electrically operated door.

9. DO NOT place fingers or hands into open section joints when

closing a door. Use lift handles/gripping points when operating

door manually.

10. DO NOT permit children to operate garage door or door

controls. Severe or fatal injury could result, should the child

become entrapped between the door and the floor.

11. Due to constant extreme spring tension, DO NOT attempt any

adjustment, repair or alteration to any part of the door,

especially to springs, spring brackets, bottom corner brackets,

red colored fasteners, cables or supports. To avoid possible

severe or fatal injury, have any such work performed

by a trained door systems technician using proper tools and

instructions.

12. On electrically operated doors, pull down ropes must be

removed and locks must be removed or made inoperative in

the open (unlocked) position.

13. Top section of door may need to be reinforced when attaching

an electric opener. Check door and/or opener manufacturer’s

instructions.

14. VISUALLY inspect door and hardware monthly for worn and or

broken parts. Check to ensure door operates freely.

15. Test electric opener’s safety features monthly, following

opener manufacturer’s instructions.

16. NEVER hang tools, bicycles, hoses, clothing or anything else

from horizontal tracks. Track systems are not intended or

designed to support extra weight.

After installation is complete, fasten this manual

near garage door.

Table of Contents

Important Safety Instructions .................................................. 2

Package Contents ................................................................... 3

Door Section Identification ...................................................... 4

Tools Required ........................................................................ 5

Pre-Installation ..................................................................5-10

Removing The Old Door .......................................5-9

Preparing The Opening ......................................... 10

Installation ......................................................................11-35

Optional Installations .......................................................36-44

TorqueMaster® Plus Reset Intructions ..............36-38

Side Lock ............................................................. 39

DoormasterTM Bracket ........................................... 39

Step Plate ............................................................. 40

Pull Rope .............................................................. 41

Trolley Instructions For Standard Lift ..................... 42

Trolley Instructions For Low Headroom ................. 43

Trolley Operator .................................................... 44

Maintenance ....................................................................45-46

Cleaning ............................................................... 45

Painting Instructions ........................................45-46

Warranty ............................................................................... 47

Dealer Locator Information.................................................... 48

WARNING

WARNING

3

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

Package Contents

(1)TORQUEMASTER® SPRING TUBE

DOOR SECTIONS (AS REQUIRED)

(2) TOP BRACKET SLIDES

1/4”-14 X 5/8” SELF TAPPING

SCREWS (AS REQUIRED)

1/4”-20 X 11/16” SELF DRILLING

SCREWS (AS REQUIRED)

(4) 1/4”-20 X 5/8”

CARRIAGE BOLTS

(4) 1/4”-20 X 9/16” LARGE

HEAD RIBBED TRACK BOLTS

(2) VERTICAL

TRACKS RH/LH

(2) 3/8”-16 X 3/4”

TRUSS HEAD BOLTS

(1) CENTER BRACKET

ASSEMBLY

(2) FULLY ADJUSTABLE RH/LH

FLAGANGLES (AS REQUIRED)

(2) QUICK INSTALL RH/LH

FLAGANGLES (AS REQUIRED)

(2) HORIZONTAL TRACKS RH/LH

NOTE: DEPENDING ON THE DOOR MODEL, SOME PARTS LISTED WILL NOT BE SUPPLIED IF NOT

NECESSARY. REAR SUPPORTS MAY NOT BE INCLUDED WITH YOUR DOOR.

ROLLERS

(AS REQUIRED)

IDRIVE® OPERATOR

(SOLD SEPARATELY)

(1) OPERATOR BRACKET

(2) HORIZONTAL ANGLES

(21-15/16” OR 80”)

(AS REQUIRED)

(2) TOP BRACKET BASES

PULL ROPE

(IF INCLUDED)

5/16” X 1 5/8” HEX HEAD LAG

SCREWS (AS REQUIRED)

WEATHER SEAL & NAILS

(IF INCLUDED)

ASYMMETRICAL U-BAR

(IF REQUIRED)

TorqueMaster® - Single and Double Spring

Installation Instructions and Owner’s Manual

9100, 9600, 5120, 5140

IMPORTANT NOTICE!

Read these instructions carefully before

attempting installation. If in question about

any of the procedures, do not perform the

work. Instead, have a qualifi ed door agency

do the installation or repairs.

© Copyright 2005 Wayne-Dalton Corp. Part No. 302868 Rev. 2 08/04/2005

MANUAL

1/4”- 20 FLANGED HEX

NUTS (AS REQUIRED)

U-BAR

(IF REQUIRED)

Q.I. JAMB BRACKETS

(AS REQUIRED)

DRUM WRAPS

(1) RIGHT & (1) LEFT

(2) 3/8”- 16 HEX NUTS

END BRACKETS

(1) RIGHT & (1) LEFT

WARNING

Rachet Bracket is under

EXTREME SPRING TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s) read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

P/N 300547

WARNING

Rachet Bracket is under

EXTREME SPRING TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s) read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

P/N 300547

CABLE DRUM ASSEMBLIES

(1) RIGHT & (1) LEFT

(1) LOOSE WINDING SHAFT

(SINGLE SPRING ONLY)

(2) 5/16”HEX NUTS 5/16” X 18 X 3/4”

CARRIAGE BOLTS

(AS REQUIRED)

5/16”X 1-1/4” CLEVIS

PIN & COTTER PIN

Tools Needed:

4

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#1 END

HINGE

#2 END

HINGE

#3 END

HINGE

#4 END

HINGE

ASTRAGAL

BOTTOM

BRACKET

BOT. LOCK

1 3/8” 1 19/32”

INT. INT.

(USED ONLY

ON FIVE

SECTIONS)

1 1/8”

7/8”

SECTION SIDE VIEW

TYPICAL HINGE STAMPING LOCATION

Door Section Identification

TOP SECTION

INTERMEDIATE SECTION

LOCK SECTION

BOTTOM SECTION

BOTTOM BRACKET

WARNING LABELS

ASTRAGAL

#3

#2

#1

WARNING LABEL

WARNING LABEL

NOTE: This provides an alternative

method for identifying your door

sections/stacking 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 also be used in conjunction

with identifying each sections.

The BOTTOM SECTION can be

identified by #1 end hinges, the factory

attached bottom astragal, and by the

bottom bracket warning labels on each

end stile.

The LOCK SECTION can be identified

by #2 end hinge.

The INTERMEDIATE SECTION can be

identified by #3 end hinges. The section

will have a warning label attached to

either the right or left hand end stile.

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 and U-bar attached to the top

section.

5

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

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.

DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO

PREVENT UNINTENDED DOOR OPERATION. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.

COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL

SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.

IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS, OR SEVERE INJURY COULD RESULT

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 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.

Tools Required

Removing An Old Door

WARNING

WARNING

WARNING

WARNING

POWER DRILL RATCHET WRENCH PLIERS/WIRE CUTTERS

PHILLIPS HEAD SCREWDRIVER PENCIL

1/8”, 3/16” DRILL BITS

FLAT TIP SCREWDRIVER

7/16” SOCKET DRIVER

TAPE MEASURE

NEEDLE NOSE PLIERS

7/16”, 1/2”, 9/16”

SOCKETS

3/8”, 7/16”, 1/2”, 9/16”

WRENCHES

SAFETY GLASSES

STEP LADDER

PRE-INSTALLATION

WARNING

VICE GRIPS VICE CLAMPS

GLOVES

(2) SAW HORSES

HAMMER

Tools Needed:

6

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

APPROVED WINDING BAR

TORSION SPRING ASSEMBLY

WINDING CONE

SET SCREWS

FIRMLY HOLD WINDING BARS AND

CAUTIOUSLY LOOSEN SET SCREWS

P1

Approved

Winding Bars

3/8” Wrench

Vice Clamp

Recommended

tools from

page 5

FAILURE TO USE APPROVED

WINDING BARS CAN CAUSE SPRING

ENERGY TO BE RELEASED

SUDDENLY, RESULTING IN SEVERE

OR FATAL INJURY.

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 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 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 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

contacts 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 contacts

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

completing this step.

Torsion Spring Removal

For Standard Lift

WARNING

WARNING

Tools Needed:

7

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

PRE-INSTALLATION

Fig. 2

Fig. 1

Fig. 3

RIGHT HAND

CABLE DRUM

TORQUEMASTER®

SPRING TUBE

CHECK CABLE

TENSION

LOOSEN LOCK

NUT 1/4 TURN 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)

PRY COUNTER GEAR

AND COUNTER COVER

FROM END BRACKET

USING FLAT TIP

SCREWDRIVER

COUNTER

GEAR

COUNTER

COVER

P2

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 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 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 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® Spring Tube

TorqueMaster® Spring Removal

Recommended

tools from

page 5

Tools Needed:

8

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Fig. 5

Fig. 6

Fig. 7

REMOVE TOP

LAG SCREW

REMOVE

BOTTOM LAG

SCREW

USE LOCKING PLIERS

TO HOLD END BRACKET

REMOVE #10

PHILLIPS HEAD

SCREW

PRY END BRACKET FROM WINDING

SHAFT USING A FLAT TIP SCREW

DRIVER AND LOCKING PLIERS

HOLD THE

END BRACKET

STEADY WITH

LOCKING PLIERS

REMOVE CABLE DRUM AND

WINDING SHAFT

DRAPE CABLE

ACROSS

TOP OF FLAGANGLE

LIFT

TORQUEMASTER®

SPRING TUBE

OFF FLAGANGLE

CENTER

BRACKET

ASSEMBLY

(2) 5/16” X 1-5/8”

HEX HEAD LAG

SCREWS

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.

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 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).

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.

TorqueMaster® Spring

Removal continued...

Recommended

tools from

page 5

9

Tools Needed:

Tools Needed:

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

Removing the Old Door

Extension Spring Removal

TOP BRACKET

HINGES

HORIZONTAL TRACK

BOTTOM SECTION

(DOOR OPEN)

CAREFULLY REMOVE “S”

HOOK AND COUNTREBALANCE

CABLE (REPEAT FOR THE

OPPOSITE SIDE)

HORIZONTAL ANGLE

REMOVE LAG SCREW

FROM SAFETY CABLE (IF

INSTALLED). REPEAT FOR

OPPOSITE SIDE.

P3

P4

Recommended

tools from

page 5

Recommended

tools from

page 5

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: Continue with “P4” after completing

this step.

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.

Tools Needed:

10

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

HEADROOM REQUIREMENT

FAILURE TO SECURELY

ATTACH A SUITABLE MOUNTING PAD TO

STRUCTURALLY SOUND FRAMING COULD CAUSE

SPRINGS TO VIOLENTLY PULL MOUNTING PAD

FROM WALL, RESULTING IN SEVERE OR FATAL

INJURY.

If you just removed your existing door or you are installing a

new door, complete all steps in PREPARING THE OPENING.

For detailed technical information regarding the opening

preparation, refer to the DASMA Technical Data Sheet TDS

#161 “Connecting Garage Door Jambs to Building Framing”

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” (89 mm).

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® counterbalance 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: Cut three (3) pieces of weather seal (may not

be included) to the jambs and header. Align the jamb seals with

the inside edge of the opening. Temporarily nail the weather

seal to the jamb to keep the bottom section from falling out of

the opening during installation.

NOTE: Do not permanently attach weather seal to the jamb

at this time.

HEADROOM REQUIREMENT: Headroom is defined as the space

needed above the top of the door for tracks, springs, etc. to allow

the door to open properly. If the door is to be motor operated,

2-1/2” (64 mm) of additional headroom is required.

NOTE: 6” LHR Conversion Kit is available for 12” Radius only.

Contact your local Wayne-Dalton dealer.

BACKROOM REQUIREMENT: Backroom is defined as the

distance needed from the opening back into the garage to

allow the door to open fully.

Preparing the Opening

WARNING

TRACK TYPE TorqueMaster®

15” Radius track 11-3/4” (299 mm)

12” Radius track 10-1/2” (267 mm)

6” LHR Kit†6” (152 mm)

DOOR HEIGHT TRACK MANUAL

LIFT

MOTOR

OPERATED

6’5”, 6’6”, 7’0” 12”, 15” Radius 98”

(2489 mm)

120”

(3048 mm)

7’6”, 8’0” 12”, 15” Radius 110”

(2794 mm)

132”

(3353 mm)

WEATHER SEAL

BACKROOM REQUIREMENT

HEADROOM

BACKROOM

DOOR

WIDTH

DOOR

HEIGHT

LEVEL HEADER

PLUMB JAMBS

HEADER BOARD

2” X 6” LUMBER

PREFERRED

SUITABLE MOUNTING

SURFACE 2” X 6”

LUMBER MINIMUM

P5

Recommended

tools from

page 5

HEADER

JAMB

JAMB

QUICK INSTALL TRACK

JAMB

WEATHER

SEAL

11

Tools Needed:

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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 recommended 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.

INSTALLATION

None

Attaching Quick Install Flag

Angles to Vertical Track

NOTE: If you have fully adjustable

flagangles, skip this step and complete

Step 2.

Place the lower quick install tab of the

flagangle in the quick install feature of

the vertical track. Give the flagangle 1/4

turn to lock in place. Repeat for other

side.

NOTE: After completing this step,

continue with Step 3.

QUICK INSTALL TAB UNLOCKED QUICK INSTALL TAB LOCKED

FLAGANGLE

VERTICAL

TRACK

1

LEFT HAND TRACK AND FLAGANGLE RIGHT HAND TRACK AND FLAGANGLE

FLAGANGLE

VERTICAL

TRACK

Tools Needed:

12

Tools Needed:

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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.

NOTE: For larger doors, a full length

horizontal angle may not be spot welded

to the horizontal track. If the horizontal

angle is not welded, the horizontal angle

will be installed as shown.

NOTE: If you have riveted track, skip

step 4 and proceed to step5.

Horizontal Angle

Hammer

HORIZONTAL

TRACK

HORIZONTAL

ANGLE

HORIZONTAL ANGLE

HORIZONTAL TRACK HOLE

HOLE

Attaching Fully Adjustable

Flagangles to Vertical Track

1/4”- 20

FLANGE HEX

NUTS

NOTE: If quick install flagangles was

installed in Step 1, skip this step and

continue with Step 3. If not, complete

this step.

Hand tighten the flagangle to the vertical

track using (2) 1/4” - 20 x 9/16” large

head ribbed track bolts and (2) 1/4” - 20

flange hex nuts. Repeat for other side.

Secure the flange nuts after flagangle

spacing is complete (Step 13).

FULLY ADJUSTABLE FLAGANGLE

1/4” - 20 X 9/16”

LARGE HEAD RIBBED

TRACK BOLTS

None

VERITCAL TRACK

TABS

KEY SLOT

2

3

HORIZONTAL

TRACK

TABS

HORIZONTAL

TRACK

HORIZONTAL

ANGLE

13

Tools Needed:

Tools Needed:

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INSTALLATION

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. 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.

Installing Q.I. Jamb Brackets

TOP

HOLE

BOTTOM

HOLE

MIDDLE

HOLE

JAMB BRACKET SCHEDULE

DOOR

HEIGHT

1ST SET 2ND SET 3RD SET

JAMB BKT POSITION JAMB BKT POSITION JAMB BKT POSITION

6’0” 64” TRACK

(1626 mm) QIJB - 5 MIDDLE QIJB - 6 BOTTOM NOT APPLICABLE

6’5” 69” TRACK

(1753 mm) QIJB - 3 BOTTOM QIJB - 6 MIDDLE NOT APPLICABLE

6’8” 72” TRACK

(1829 mm) QIJB - 3 BOTTOM QIJB - 6 MIDDLE NOT APPLICABLE

7’0” 76” TRACK

(1930 mm) QIJB - 3 BOTTOM QIJB - 7 TOP NOT APPLICABLE

7’3” 79” TRACK

(2007 mm) QIJB - 3 BOTTOM QIJB - 5 BOTTOM QIJB - 6 BOTTOM

7’6” 82” TRACK

(2083 mm) QIJB - 3 BOTTOM QIJB - 5 BOTTOM QIJB - 6 BOTTOM

7’9” 85” TRACK

(2159 mm) QIJB - 3 BOTTOM QIJB - 5 BOTTOM QIJB - 6 BOTTOM

8’0” 4 SECTIONS

88” TRACK (2235 mm) QIJB - 3 MIDDLE QIJB - 6 TOP QIJB - 7 MIDDLE

8’0” 5 SECTIONS

88” TRACK (2235) QIJB - 3 BOTTOM QIJB - 7 TOP QIJB - 8 TOP

3RD SET HOLES

2ND SET HOLES

1ST SET HOLES

None

4

Drums

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 even with door section.

None

LEFT HAND TORQUEMASTER®

COUNTERBALANCE DRUM

BOTTOM

SECTION

MILFORD PIN

#1 END HINGE

(HINGE TUBE)

BOTTOM BRACKET

BOTTOM

SECTION

ASTRAGAL

5

QUICK INSTALL FEATURE

QI JAMB BRACKET

TWISTLOCK TAB

LEFT SIDE SHOWN RIGHT SIDE SHOWN

COUNTERBALANCE

CABLE

ROLLERS

BOTTOM

SECTION

Tools Needed:

14

Tools Needed:

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Bottom Section

Before installing the bottom section,

the weather seal (may not be included)

must be installed (see PREPARING THE

OPENING on page 10)

Center the bottom section in the door

opening. Level section using wooden

shims (if necessary) under the bottom

section.

Level

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 1-5/8” lag screws.

Tighten lag screw securing bottom

jamb bracket to jamb, to maintain

5/8” spacing. Hang cable drum over

flagangle. Repeat for the right hand

side.

BOTTOM SECTION

BOTTOM SECTION

VERTICAL TRACK

ROLLER

5/16” X 1-5/8”

LAG SCREWS

FLAGANGLE

VERTICAL

TRACK

ASSEMBLY

CABLE

JAMB

BRACKET

3/16” Drill Bit

Power Drill

7/16” Socket

Driver

Tape Measure

Level

5/8”

6

7

BOTTOM SECTION

DOOR OPENING

WEATHER SEAL

15R QI FLAGANGLE

12R QI FLAGANGLE

12R & 15R FULLY

ADJUSTABLE FLAGANGLE

LAG

SCREW

LOCATIONS

LAG

SCREW

LOCATIONS

LAG

SCREW

LOCATIONS

WOODEN SHIMS

(IF NECESSARY)

LEVEL

LAG

SCREW

QUICK INSTALL

JAMB BRACKET

CABLE DRUM

15

Tools Needed:

Tools Needed:

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INSTALLATION

Stacking Sections

NOTE: For door section identification see

page 4.

NOTE: Make sure hinges are flipped down,

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

using 1/4”-14 x 5/8” self tapping screws.

Repeat for other section(s) except top

section.

IMPORTANT: PUSH & HOLD THE HINGE

LEAF AGAINST SECTION WHILE SECURING

WITH 1/4”-14 X 5/8” SELF TAPPING

SCREWS. END HINGES HAVE (2) SCREWS

AND INTERMEDIATE HINGES HAVE (3)

SCREWS.

NOTE: Install lock at this time (sold

separately) see instructions in OPTIONAL

SIDELOCK INSTALLATION on page 40.

LOCK SECTION

8

(2) 1/4”-14 X 5/8”

SELF TAPPING SCREWS

END HINGES (LEFT HAND SHOWN, RIGHT

HINGE SYMMETRICALLY OPPOSITE) INTERMEDIATE HINGES

Top Brackets

(4) 1/4” - 14 x 5/8”

SELF TAPPING

SCREWS

TOP BRACKET BASE

TOP BRACKET SLIDE

(2) 1/4” - 20

FLANGED HEX

NUTS

(2) 1/4” - 20 x 5/8”

CARRIAGE BOLTS

ROLLER

TOP BRACKET SLIDE

Power Drill

7/16” Socket

Driver

Power Drill

7/16” Socket

Driver

1ST SET

2ND SET

To install the L-shaped top brackets,

align the top holes in the top bracket

base with the second set of holes in the

endcap of the top section.

Fasten using (4) 1/4” - 14 x 5/8” self

tapping screws. Secure the top bracket

slide to the bracket base loosely using

(2) 1/4” - 20 x 5/8” carriage bolts and

(2) 1/4” - 20 flanged hex nuts. The

bracket will be tightened and adjusted

in Step 16. Insert rollers into top bracket

slide. Repeat for other side.

9

(3) 1/4”-14 X 5/8” SELF TAPPING

SCREWS

TOP SECTION

TOP SECTION

TOP SECTION

Tools Needed:

16

Tools Needed:

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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.

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

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.

NOTE: If a 3” U-Bar was installed in Step

10, skip this step.

NOTE: Model 9400/9600 glazed top

doors 13’-0” wide or greater will be

supplied with a 3” asymmetrical u-bar

for the top section.

Place the 3” asymmetrical u-bar over the

top rib. Fasten each end of the u-bar to

the 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 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)

U-Bar

U-Bar - Asymmetrical

(2) 1/4”-20 X 11/16”

SELF DRILLING SCREWS

Power Drill

7/16” Socket

Driver

Power Drill

7/16” Socket

Driver

(2) Saw Horses

10

11

U-BAR

OPERATOR BRACKET

(INSTALLED IN THE STEP 12)

TOP DOOR SECTION

6”

6”

ATTACHING CENTER OF U-BAR ATTACHING ENDS OF U-BAR

(2) 1/4”-20 X 11/16”

SELF DRILLING

SCREWS

(2) 1/4”-20 X 5/8” SELF

TAPPING SCREWS

U-BAR

OPERATOR BRACKET

(INSTALLED IN THE STEP 12)

TOP DOOR SECTION

30” TO 36”

6”

6”

ATTACHING CENTER OF U-BAR ATTACHING INTERMEDIATES OF U-BAR

(2) 1/4”-20 X 5/8”

SELF TAPPING

SCREWS

(2) 1/4”-20 X 5/8”

SELF TAPPING

SCREWS

Tools Needed:

17

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INSTALLATION

12

Power Drill

7/16” Socket

Driver

Vice Clamps

Phillips Head

Screwdriver TOP

SECTION

WITH OR

WITHOUT

U-BAR

ALIGN CENTER OF BOTH TABS WITH

CENTER LINE OF TOP SECTION

OPERATOR

BRACKET U-BAR

TOP

SECTION

OPERATOR

BRACKET

MALE PART OF

TOP SECTION

(2) #12 X 1/2”

PHILLIPS HEAD

SCREWS

VICE CLAMP

NOTE: NOT REQUIRED

FOR J-STRUTS.

OPERATOR BRACKET

Operator Bracket

NOTE: Operator bracket must be

mounted and secured prior to installing

top section.

IMPORTANT: WHEN CONNECTING A

TROLLEY TYPE GARAGE DOOR OPENER

TO THIS DOOR, A WAYNE-DALTON

OPENER/TROLLEY BRACKET MUST

BE SECURELY ATTACHED TO THE TOP

SECTION OF THE DOOR, ALONG WITH

ANY U-BARS PROVIDED WITH THE

DOOR. THE INSTALLATION OF THE

OPENER MUST BE ACCORDING TO

MANUFACTURER’S INSTRUCTIONS AND

FORCE SETTINGS MUST BE ADJUSTED

PROPERLY

Prior to installing top section, locate the

center of the top section and seat the

operator bracket on male part of the top

section. For retro fit applications, the

operator bracket must be aligned with

an existing operator and positioned on

top section so it bridges the transition

point of the section thickness, as shown

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

shown in FIG. 1.5. Then attach (2) 1/4”

- 14 x 5/8” self-tapping screws to the

operator bracket, as shown in FIG. 1.6.

Remove vice clamps.

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 shown 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 FIG. 1.7 for installing operator

bracket on top section without u-bars.

FIG. 1.1

FIG. 1.3

FIG. 1.5

FIG. 1.2

FIG. 1.4

FIG. 1.6

FIG. 1.7

OPPOSITE SIDE OF

OPERATOR BRACKET

(2) 1/4” - 20 X 11/16”

SELF-DRILLING SCREWS

OPERATOR

BRACKET

(2) 1/4” - 14 X 5/8”

SELF-TAPPING

SCREWS

(4) 1/4” - 14 X 5/8”

SELF-TAPPING

SCREWS

OPERATOR

BRACKET

OPERATOR

BRACKET

(6) 1/4” - 14 X 5/8”

SELF-TAPPING

SCREWS

U-BAR

U-BAR

U-BAR

Tools Needed:

18

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Top Section

13

Hammer

DOOR WIDTH

+3-3/8” TO 3-1/2”

Place the top section in the opening.

Temporarily secure the top section

by driving a nail in the header near

the center of the door and bending it

over the top section. Now flip up hinge

leafs, hold tight against section, and

fasten center hinges first, and end

hinges last. (Refer to Step 8). When

installing a door with a TorqueMaster®

Plus counterbalance system, vertical

track alignment is critical. Position

flagangle between 1-11/16” (43 mm)

to 1-3/4” (44 mm) from the edge of

the door; tighten the bottom lag screw.

Flagangles must be parallel to the door

sections. Repeat for opposite side.

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.

For quick install track:

Complete the vertical track installation

by securing the center jamb bracket(s)

and tightening the other lag screws.

Repeat for opposite side.

For fully adjustable track:

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 track bolts and nuts. Repeat for

opposite side. FULLY ADJUSTABLE

1-11/16” TO 1-3/4”

FLAGANGLE

TOP

SECTION

NAIL

ROLLER

VERTICAL TRACK

ROLLER AGAINST

VERTICAL TRACK

TOP SECTION

Tools Needed:

19

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Attaching Horizontal Track to

Quick Install Flagangle

NOTE: If you have fully adjustable

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 horizontal track with the

quick install tab of the flagangle. Push

curved portion of horizontal track down

to lock in place.

DO NOT RAISE DOOR UNTIL

HORIZONTAL TRACKS ARE SE CURED

AT REAR, AS OUTLINED IN STEP 30, OR

DOOR COULD FALL FROM OVERHEAD

POSI TION CAUSING SEVERE OR FATAL

INJURY.

Level the horizontal track assembly and

bolt the horizontal angle to the slot in

the flagangle using (1) 3/8” - 16 x 3/4”

truss 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

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, position horizontal tracks

slightly above level.

NOTE: After completing this step,

continue with Step 16.

KEY

SLOT

QUICK

INSTALL

TAB

HORIZONTAL

TRACK

VERTICAL

TRACK

FLAGANGLE

14

WARNING

9/16” Socket

Ratchet Wrench

9/16” Wrench

Level

KEY SLOT

QUICK

INSTALL

TAB

HORIZONTAL

TRACK

VERTICAL

TRACK

FLAGANGLE

3/8” - 16 X 3/4”

TRUSS HEAD BOLT 3/8” - 16 HEX NUT

HORIZONTAL TRACK

HORIZONTAL ANGLE

INSTALLATION

Tools Needed:

20

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Attaching Horizontal Track to

Adjustable Flagangle

NOTE: If quick install flagangles were

installed in Step 14, skip this step and

continue with Step 16. If not, complete

this 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 tighten the horizontal

track to the flagangle with (2) 1/4” - 20 x

9/16” large head ribbed track bolts and

(2) 1/4”-20 flange hex nuts.

DO NOT RAISE DOOR UNTIL HORIZONTAL

TRACKS ARE SE CURED AT REAR, AS

OUTLINED IN STEP 30, OR DOOR COULD

FALL FROM OVERHEAD POSI TION

CAUSING SEVERE OR FATAL INJURY.

Level the horizontal track assembly and

bolt the horizontal angle to the slot in

the flagangle using (1) 3/8” - 16 x 3/4”

truss 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 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,

position horizontal tracks slightly above

level.

15

7/16” Socket

9/16” Socket

Ratchet Wrench

9/16” Wrench

Level

Flat Tip

Screwdriver

1/4”-20 FLANGE

HEX NUTS

FLAGANGLE

1/4” - 20 X 9/16”

LARGE HEAD

RIBBED TRACK

BOLTS

WARNING

3/8” - 16 X 3/4”

TRUSS HEAD BOLT

3/8” - 16 HEX NUT

HORIZONTAL TRACK

HORIZONTAL ANGLE

Tools Needed:

21

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INCORRECT

16 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.

HORIZONTAL

TRACK

TOP

BRACKET

SLIDE

(2) 1/4” - 20

FLANGE HEX

NUTS

CORRECT

7/16” Wrench

TOP

SECTION

TOP

SECTION

TOP

SECTION

INSTALLATIONINSTALLATION

Tools Needed:

22

Tools Needed:

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TorqueMaster® Spring Tube

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.

LABELED END

TORQUEMASTER®

SPRING TUBE

None

17

18 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 40, 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.

CENTER

BRACKET

ASSEMBLY

TORQUEMASTER®

SPRING TUBE

TORQUEMASTER®

SPRING TUBE

CENTER

BRACKET

BUSHING

None

Tools Needed:

23

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

idrive® Installation

NOTE: See idrive® main installation

instructions and owner’s manual for

idrive® parts.

IMPORTANT: RIGHT AND LEFT HAND

IS ALWAYS DETERMINED FROM INSIDE

THE GARAGE LOOKING OUT.

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

ensure the left hand bearing and the

internal (black) sleeve are aligned with

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.

Once aligned, slide the opener onto the

right hand end of the TorqueMaster®

spring tube. As the right end of the

TorqueMaster® spring tube enters the

internal (black) sleeve, rotate the

opener back and forth slightly to help

aid alignment.

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

TorqueMaster® spring tube if

misalignment occurs.

Continue sliding the opener to the

center of the TorqueMaster® spring

tube.

Plug the motor power cord into the

opener.

LEFT HAND SIDE

TORQUEMASTER® SPRING TUBE

AND BEARING PROFILES ALIGNED

RIGHT HAND END

OF TORQUEMASTER®

SPRING TUBE

RIGHT HAND SIDE

TORQUEMASTER®

SPRING TUBE AND

BEARING PROFILES

ALIGNED

PLUG-IN MOTOR

POWER CORD

MOTOR

19

INSTALLATION

Tools Needed:

24

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IMPORTANT: RIGHT AND LEFT HAND

IS ALWAYS DETERMINED FROM INSIDE

THE GARAGE LOOKING OUT.

Drum wraps are identified as right and

left.

Slide the left hand drum wrap over the

left side of the TorqueMaster® spring

tube assembly with the tabs facing

left. Continue sliding the left hand

drum wrap towards the center of the

TorqueMaster® spring tube assembly.

Slide the right hand drum wrap over the

right side of the TorqueMaster® spring

tube assembly with the tabs facing

right. Continue sliding the right hand

drum wrap towards the center of the

TorqueMaster® spring tube assembly.

TORQUEMASTER®

SPRING TUBE ASSEMBLY

TABS

LEFT HAND DRUM WRAP

Drum Wraps

None RIGHT HAND DRUM WRAP

LEFT HAND DRUM WRAP

20

Tools Needed:

25

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

21

Shake the TorqueMaster® spring tube

assembly gently to extend the winding

shafts out about 5" on each side. For

single spring applications, there will be

no left hand spring in the

TorqueMaster® spring tube assembly.

Lift the TorqueMaster® spring tube

assembly and rest it on the top of the

flagangles.

NOTE: Cable drums are marked right

and left hand. Cable drums and

TorqueMaster® spring tube assembly

are cam shaped to fit together only one

way.

IMPORTANT: RIGHT AND LEFT HAND

IS ALWAYS DETERMINED FROM INSIDE

THE GARAGE LOOKING OUT.

To install the cable drum, slide the

correct cable drum over the winding

shaft until the cable drum seats against

the TorqueMaster® spring tube

assembly.

The winding shaft must extend past the

cable drum far enough to expose the

splines and the groove. Align the

winding shaft groove with the round

notch in the flagangle.

For double spring applications:

Repeat for opposite side.

For single spring applications: Insert

the loose winding shaft into the left

hand cable drum prior to sliding the

cable drum over the TorqueMaster®

spring tube assembly.

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 assembly.

WINDING

SHAFT

RIGHT DRUM

5”

WINDING SHAFT

CABLE

DRUM

GROOVE

ROUND NOTCH

FLAGANGLE

SPLINES

COUNTERBALANCE CABLE

Cable Drums

LOOSE WINDING SHAFT

Tape Measure

TORQUEMASTER®

SPRING TUBE ASSEMBLY

TORQUEMASTER®

SPRING TUBE ASSEMBLY

GROOVE

CABLE

DRUM

SPLINES

WINDING SHAFT

INSTALLATIONINSTALLATION

Tools Needed:

26

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Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration, in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

IMPORTANT: WARNING TAGS MUST BE

SECURELY ATTACHED TO BOTH END

BRACKETS.

End brackets are right and left hand.

You can identify the right hand end

bracket by the disconnect cable guide

hole in the top of the bracket.

Attach TorqueMaster® warning tags to

both end brackets prior to installing.

Beginning with either side, slide the

end bracket onto the winding shaft so

that the grooves in the ratchet wheel fit

onto the winding shaft splines.

Secure end bracket to the jamb using

(1) 5/16” x 1-5/8” hex head lag screw

and (1) 5/16”-18 x 3/4” carriage bolt

and hex nut.

Repeat for other end bracket.

SPLINES WINDING

SHAFT

GROOVE

DISCONNECT

CABLE GUIDE

HOLE

RIGHT END

BRACKET

WARNING TAG

22 End Brackets

Power Drill

7/16” Socket

Driver

5/16” Wrench

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER

POSITION SIDE VIEW

Rat

chet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration, in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

RIGHT END

BRACKET

RATCHET

WHEEL

TEETH POINTING

UPWARD

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration, in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

5/16” X 1-5/8”

HEX HEAD LAG 5/16”-18 x 3/4”

CARRIAGE BOLT

AND HEX NUT

RIGHT END

BRACKET

Tools Needed:

27

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23 CENTER

BRACKET

BUSHING

ASSEMBLY

(2) 5/16” X 1-5/8”

HEX HEAD LAG

SCREWS

NOTE: If you are installing the idrive®

opener on your garage door, skip this step

and continue with Step 24.

NOTE: If you are not installing the

idrive® opener on your garage door, you

must install the center bracket bushing

assembly. Follow these instructions for

non-idrive® operated garage doors.

NOTE: If you are installing a DoorMaster™

opener, see optional DoorMaster™ Bracket

installations on page 40, 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 28.

Securing Center Bracket

Assembly

INSTALLATION

Power Drill

1/8” Drill Bit

7/16” Socket

Driver

Tools Needed:

28

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Positioning Support Bracket

24

USING A TAPE MEASURE, MAINTAIN AN EQUAL MEASUREMENT “X”

(TOP OF DOOR TO BOTTOM OF TORQUEMASTER® TUBE) AT BOTH

ENDS AND THE CENTER.

TOP SECTION

“X” “X”

NOTE: See idrive® main installation

instructions and owner’s manual for

idrive® parts.

NOTE: idrive® must be installed on a

solid mounting surface.

Locate the mounting surface. The

mounting surface is a vertical board

running directly above the center of the

door. Remove (2) 1/4”-20 flange nuts

from bottom of opener.

NOTE: Do not discard flange nuts.

Place the support bracket underneath

opener, to the right side of motor,

centered on mounting surface. Using a

tape measure, level the bottom of the

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 the lag screws. Then

secure support bracket to the mounting

surface with (2) 1/4” x 1-1/2" lag

screws.

IMPORTANT: TORQUEMASTER® SPRING

TUBE MUST BE LEVEL AFTER SUPPORT

BRACKET IS FASTEN TO MOUNTING

SURFACE.

NOTE: If wood mounting surface is

behind dry wall, use 1/4” x 2” lag

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.

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.

Power Drill

1/8” Drill Bit

7/16” Socket

Driver

MOUNTING

STUDS BRACKET

SLOTS

SUPPORT

BRACKET

TORQUEMASTER®

SPRING TUBE

(2) 1/4” - 20

FLANGE NUTS

“X”

ANTENNA WIRE

45° ANGLE

1/4 X 1-1/2”

LAG

SCREWS

SUPPORT

BRACKET

1/4” - 20

FLANGE

NUTS

MOUNTING

STUDS

MOUNTING

SURFACE

(HEADER)

TOP OF DOOR

TORQUEMASTER®

SPRING TUBE

29

Tools Needed:

Tools Needed:

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

NOTE: See idrive® main installation

instructions and owner’s manual for

idrive® parts.

Attach the loose disconnect cable

(located in opener hardware bag) to the

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

bracket.

Attaching Disconnect Cables

Pliers

Mounting Disconnect

Handle Bracket

Pencil

Tape measure

1/8” Drill Bit

7/16” Socket

Driver

Power Drill

6ft6ft

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

NOTE: See idrive® main installation

instructions and owner’s manual for

idrive® parts.

Mark a location on the right jamb, 6

feet above the floor to mount the

disconnect handle bracket.

Drill 1/8” pilot holes for the lag screws.

Align top of the bracket with the mark.

Fasten bracket to the jamb with

(2) 1/4” x 1-1/2" lag screws.

(2) 1/4” X 1-1/2”

LAG SCREWS

DISCONNECT

HANDLE BRACKET

25

26

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITIONLOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration,

in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

DISCONNECT

CABLE

S-HOOK

HOLE IN RIGHT

END BRACKET

CLOSE “S” HOOK

HOLE IN

END BRACKET

RIGHT SIDE OF

END BRACKET

INSTALLATION

Tools Needed:

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

NOTE: See idrive® main installation

instructions and owner’s manual for

idrive® parts.

NOTE: Bring motor to the down position

by pulling the disconnect cable, insure

opener disconnect teeth are engaged

before installing disconnect handle.

Start the #6-20 x 1/2" screw into the

disconnect handle. Thread the

disconnect cable through the top of the

disconnect handle bracket and then the

disconnect handle.

Locate the disconnect handle in full

upper position of disconnect handle

bracket.

Remove all disconnect cable slack

between the opener and the top of the

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

disconnect handle. Trim off excess cable

from bottom of the disconnect handle.

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.

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 instructions and owner’s

manual of your idrive® opener

Attaching Disconnect Handle

Phillips head

screwdriver

Wire cutters

#6-20 X 1/2”

SCREW

DISCONNECT

HANDLE

BRACKET

DISCONNECT

CABLE

HANDLE

MANUAL OPERATED POSITION

UPPER POSITION

EMERGENCY DISCONNECT

LABEL

MOTOR OPERATED POSITION

27

31

Tools Needed:

Tools Needed:

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Place vice clamps onto both vertical

tracks just above the third roller. This is

to prevent the garage door from raising

while winding counterbalance springs.

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).

Securing Door

for Spring Winding

TRACK

VICE CLAMPS

ATTACHED TO

INNER RAIL

OF TRACK

Vice Clamps

WARNING

28

PLACE VICE

CLAMPS ABOVE

3RD ROLLER

INSTALLATION

Starting on the right side, adjust the

cable drum assembly by rotating the

drum until the set screw faces directly

away from the header. Loosen the set

screw no more than 1/2 turn.

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, and then tighten an additional

1-1/2 turns.

Cut off excess cable.

IMPORTANT: ENSURE THE CABLE IS

ALIGNED AND SEATED IN THE FIRST

GROOVE OF THE CABLE DRUM PRIOR

TO WINDING SPRINGS.

NOTE: Illustrations show the right

TorqueMaster® Plus drum, left

TorqueMaster® Plus drum is

symmetrically opposite.

29 Cable Adjustment

Pliers/Wire

Cutters

Flat Tip

Screwdriver

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration,

in conjunction with the Instructions on the other side of

this label.

WA

RNING

Rachet B

racket is under

EXTREM

E SPRING

TEN

SION.

To avoid

possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

SET SCREW

FIRST GROOVE

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration, in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

SET SCREW

PLIERS

COUNTERBALANCE CABLE

IN FIRST GROOVE

CAM PEAK STRAIT UP

COUNTERBALANCE

CABLE

Tools Needed:

32

Tools Needed:

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

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration, in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

31 Winding Springs

Ratchet

5/8” Socket

3” Extension

Gloves

RECOMMENDED SPRING TURNS

Door Height Spring Turns

6’-0” 14

6’-3” 14-1/2

6’-5” 15

6’-6” 15

6’-8” 15-1/2

6’-9” 15-1/2

7’-0” 16

7’-3” 16-1/2

7’-6” 17

7’-9” 17-1/2

8’-0” 18

END BRACKET

RATCHET

3”

EXTENSION

5/8” SOCKET

MARKS

None

To install drum wraps, position the left

hand drum wrap over the left hand

drum, align with counterbalance cable;

slide groove in drum wrap towards the

left until tabs snap over drum in

between drum and ratchet gear. Repeat

for right hand side.

IMPORTANT: RIGHT AND LEFT HAND

ARE ALWAYS DETERMINED FROM

INSIDE THE GARAGE LOOKING OUT.

Drum Wrap Installation

30

IT IS RECOMMENDED THAT LEATHER

GLOVES BE WORN WHILE WINDING

THE TORQUEMASTER® PLUS SPRINGS.

FAILURE TO WEAR GLOVES MAY CAUSE

INJURY TO HANDS.

Double check to ensure the

counterbalance cable is aligned in the

first groove of the cable drum Step 29.

Starting with the right hand side, place

a mark on winding shaft (or socket) and

end bracket.

Turn the pawl knob on the end bracket

to the upper position. (See page 33)

Using a ratchet wrench with a 5/8“

socket (NOTE: A 3” extension is also

recommended for added clearance from

the horizontal angle.), wind the spring

by rotating the winding shaft counter

clockwise, while watching the mark on

the winding shaft.

WARNING

DRUM WRAP

(LEFT HAND)

DRUM

(LEFT HAND)

GROOVE

IN DRUM

TABS

COUNTERBALANCE

CABLE

PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, ENSURE

YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE INSTAL-

LATION INSTRUCTIONS. OTHERWISE THE SPRING FITTINGS MAY RELEASE

FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND COULD

RESULT IN SEVERE OR FATAL INJURY.

WARNING

Tools Needed:

33

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Winding Springs Continued...

PAWL KNOB IN LOWER

POSITION

END BRACKET

PAWL KNOB IN UPPER

POSITION

END BRACKET

Spring Turns

Door Height Spring Turns

(6’ - 0”) 14

(6’ - 3”) 14 - 1/2

(6’ - 5”) 15

(6’ - 6”) 15

(6’ - 8”) 15 - 1/2

(6’ - 9”) 15 - 1/2

(7’ - 0”) 16

(7’ - 3”) 16 - 1/2

(7’ - 6”) 17

(7’ - 9”) 17 - 1/2

(8’ - 0”) 18

Number of Installed Spring Turns LOCATION FOR

MARKING NUMBER

OF INSTALLED

SPRING TURNS

BACK OF TORQUEMASTER® PLUS END BRACKET WARNING TAG

INSTALLATION

IMPORTANT: PAWL KNOB MUST BE

IN UPPER POSITION TO ADD/ REMOVE

REQUIRED NUMBER OF SPRING TURNS.

After 2-3 turns, remove the ratchet

wrench and adjust the cable on the left

side (STEP 29). Ensure the cables are in

the first groove and the cable drums, as

shown in Step 29.

NOTE: Single spring application require

no spring winding on the left hand side,

but meed cable tension adjustments.

IMPORTANT: COUNTERBALANCE

CABLE TENSION MUST BE EQUAL ON

BOTH SIDES PRIOR TO FULLY WINDING

SPRINGS.

SEE THE SPRING TURN CHART FOR

THE REQUIRED NUMBER OF TURNS:

For single spring applications:

Return to the right hand and continue

winding the spring to the required

number of turns for your door. Place

pawl knob in lower position.

For double spring applications:

Place a mark on the winding shaft and

end bracket. Place the ratchet with

5/8” socket onto the left hand winding

shaft end. To wind the spring, rotate

the winding shaft clockwise, while

watching the mark on the winding

shaft.Rotate the winding shaft to the

required number of turns for your door.

Then return to the right hand side

and wind the right hand spring to the

required number of turns. Place pawl

knob in lower position on both sides.

IMPORTANT: Mark number of spring

turns on TorqueMaster® Plus end

bracket warning tag.

NOTE: Since total turns to balance door

can deviate from SPRING TURN CHART

values by ± 1/2 turn, adjustments to

the recommended number of turns

may be required AFTER rear hangers

assembly is completed.

IMPORTANT! HOLD THE DOOR DOWN

TO PREVENT IT FROM RISING

UNEXPECTEDLY IN THE EVENT THE

SPRING WAS OVERWOUND AND

CAUTIOUSLY REMOVE VICE CLAMPS

FROM VERTICAL TRACKS.

IMPORTANT! ADJUSTMENTS TO THE

RECOMENDED NUMBER OF TURNS

MAY BE REQUIRED. IF DOOR RAISES

OFF THE FLOOR UNDER SPRING

TENSION ALONE, THEN REDUCE

SPRING TENSION UNTIL DOOR REST

ON THE FLOOR. IF THE DOOR IS HARD

TO RAISE OR DRIFTS DOWN ON ITS

OWN, THEN AD SPRING TENSION.

Tools Needed:

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

Rear Support

31

Ratchet Wrench

1/2” Socket

1/2” Wrench

(2) Vice Clamps

Tape Measure

Level

Hammer

DOOR IN THE

UP POSITION

VERTICAL

TRACK

VICE

CLAMPS

DOOR EDGE

HORIZONTAL

TRACK

3/4”

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.

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, (2) 5/16”-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 (2) 5/16” x

2” hex head lagscrews.

NOTE: If an idrive® opener is installed,

position horizontal tracks one hole

above level when securing it to rear

supports. NOTE: 30” angle must be

attached to sound framing members

and nails should not be used.Now,

permanently attach the weather seal on

both door jambs and header

(Temporarily attached in PREPARING

THE OPENING on page 10). Avoid

pushing weather seal too tightly against

face of door.Now, lift door and check

it’s balance.

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.

WARNING

WARNING

WARNING

Tools Needed:

35

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Rear Support Continued...

PERFORATED ANGLE

(3) 5/16”

BOLTS & NUTS

HORIZONTAL TRACK

BOLT MUST EXTEND INTO

THE TRACK TO SERVE AS

A ROLLER STOP

SOUND FRAMING MEMBERS

SOUND FRAMING MEMBERS

HORIZONTAL TRACK

PERFORATED

ANGLE

BOLT MUST EXTEND INTO

THE TRACK TO SERVE AS

A ROLLER STOP

PERFORATED ANGLE -

BOLTED USING (2) 5/16”

X 1-5/8” HEX HEAD LAG

SCREWS TO CEILING

MEMBER AND PARALLEL

TO DOOR

JAMB

WEATHER

SEAL

PERMANENTLY ATTACHED

WEATHER SEAL

PERFORATED

ANGLE

PERFORATED ANGLE -

BOLTED USING (2) 5/16”

X 1-5/8” HEX HEAD LAG

SCREWS TO CEILING

MEMBER AND PARALLEL

TO DOOR

INSTALLATION

Adjust, if door lifts by itself (hard to pull

down) or if door is difficult to lift (easy to

pull down). Anytime spring adjustments

are made, ratchet pawl knob must be in

the upper position to add/remove required

number of spring turns (refer to step 29).

To adjust springs, only add or remove a

maximum of 3/10 of a turn (three teeth of

ratchet wheel) at a time. Both sides need to

be adjusted equally on double spring doors.

Add Spring Tension: The ratchet wheel is

made of 10 teeth. To add spring tension,

ensure the ratchet and socket is set so that

it will tighten counter clockwise on the right

hand side, and clockwise on the left hand

side. Place the ratchet with 5/8” socket

onto the winding shaft, pull down to add

3/10 of a turn. Watch as three teeth of the

ratchet wheel pass over the pawl, creating

three “clicks”.

Remove Spring Tension: To remove spring

tension, ensure the ratchet and socket is

set so that it will tighten counter clockwise

on the right hand side and clockwise on

the left hand side. It is recommended that

a regular 5/8” wrench be used. Place the

wrench onto the winding shaft. Pull down

on the wrench to relieve pressure between

the pawl and the ratchet wheel. Push in on

the pawl to allow the three ratchet wheel

teeth to pass by the pawl, as you carefully

allow the wrench to be rotated upward by

the spring tension. Release the pawl to

allow it to engage with the ratchet wheel.

IMPORTANT: BE PREPARED TO HOLD THE

FULL TENSION OF THE SPRING.

IMPORTANT: DO NOT ADD OR REMOVE

MORE THAN 1 SPRING TURNS (1 SPRING

TURN EQUALS 10 TEETH ON RATCHET

WHEEL) FROM THE RECOMMENDED

NUMBER OF TURNS SHOWN ON THE

SPRING TURN CHART.

If the door still does not operate easily,

lower the door into the closed position,

UNWIND SPRING(S) COMPLETELY, and

recheck the following items:

1.) Check the door for level.

2.) Check the TorqueMaster® tube and

flagangles for level and plumb.

3.) Check the distance between the

flagangles must be door width plus 3-3/8”

to 3-1/2”.

4.) Check the counterbalance cables for

equal tension adjust if necessary.

5.) Rewind the spring(s).

6.) Make sure door isn’t rubbing on jambs.

After door installation is completed, refer to

idrive® owner’s manual.

Tools Needed:

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.com

READ THESE INSTRUCTIONS CAREFULLY

BEFORE ATTEMPTING TO RESET THE

TORQUEMASTER® SYSTEM. IF IN

QUESTION ABOUT ANY OF THE

PROCEDURES, DO NOT PERFORM THE

WORK. INSTEAD, HAVE A QUALIFIED DOOR

AGENCY RESET THE SYSTEM.

ALWAYS KEEP MOVING DOOR IN SIGHT

AND KEEP PEOPLE AND OBJECTS AWAY

UNTIL IT IS COMPLETELY CLOSED. TO

PREVENT A SEVERE OR FATAL INJURY,

AVOID STANDING IN A OPEN DOOR WAY

OR WALKING THROUGH THE DOORWAY

WHILE THE DOOR IS MOVING.

KEEP THE GARAGE DOOR PROPERLY

BALANCED. AN IMPROPERLY BALANCED

DOOR COULD CAUSE SEVERE OR FATAL

INJURY. HAVE A QUALIFIED SERVICE

PERSON MAKE ADJUSTMENTS/REPAIRS

TO CABLES, SPRING ASSEMBLIES, AND

OTHER HARDWARE.

This door is equipped with a

Torquemaster® Plus system, which

provides a safety feature that prevents the

door from rapidly descending in case of

spring failure or forceful manual operation.

Typical sign of an activated system: Door

opens, but will not close; door makes a

distinct “clicking” noise upon opening. If

the system is activated, carefully follow

the reset instructions below.

1. First, locate and visual inspect the

Torquemaster® Plus end brackets to

determine if the system has engaged (see

illustration). NOTE: The Torquemaster®

Plus end brackets are located on top of

the door on the right and left hand side.

2. Disengage opener (if installed) by

pulling or placing emergency disconnect in

the manual operated position.

TorqueMaster® Plus Reset

Instructions

NO SPACE BETWEEN

DRUM PAWL AND CABLE

DRUM

INDICATES ENGAGEMENT

CABLE DRUM

DRUM PAWL

ENGAGEMENT SIDE VIEW

NO SPACE BETWEEN

DRUM PAWL AND

CABLE DRUM

ENGAGEMENT UNDERNEATH VIEW

SPACE BETWEEN DRUM PAWL

AND CABLE DRUM

NON-INDICATES ENGAGEMENT

NON-ENGAGEMENT SIDE VIEW

NON-ENGAGEMENT UNDERNEATH VIEW

5/8” Socket

Ratchet Wrench

3” Extension

Vice Clamps

(Pair)

3” Extension

WARNING

WARNING

WARNING

SPACE BETWEEN

DRUM PAWL AND

CABLE DRUM

CABLE DRUM

DRUM PAWL

RATCHET

PAWL

❉

Tools Needed:

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

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If the system is activated, follow these

steps to reset the system:

3. Clamp vice grips on both vertical tracks

just below the bottom section.

4. Flip the pawl knob on both end brackets

to the upper position (see illustration).

5. With assistance, raise the door slightly

to reset the system.

IMPORTANT: BE PREPARED TO SUPPORT

THE TOTAL WEIGHT OF THE DOOR.

6. Cautiously remove the vice clamps from

the vertical tracks; with assistance, lower

the door.

IMPORTANT: BE PREPARED TO HOLD THE

FULL TENSION OF THE SPRING.

7. Check for spring tension. Starting on the

right hand side, place a ratchet and 5/8”

socket on the Torquemaster® Plus end

bracket (see illustration). Ensure ratchet is

set so that it will tighten counter clockwise

on the right hand side, and clockwise on

the left hand side (if applicable). If ten-

sion is present, remove the ratchet and

check the left hand side (if applicable). If

spring(s) have tension, proceed to Step

8; if no spring tension is present, contact

a qualified door agency to replace the

spring(s).

NOTE: A 3” extension is also

recommended for added clearance from

the horizontal angle.

8. Lift door and check its balance. Adjust

spring(s), if door lifts by itself (hard to pull

down) or if door is difficult to lift (easy to

pull down). Anytime spring adjustments

are made, pawl knob must be in the upper

position (see illustration).

An unbalanced door such as this can

cause idrive® or Torquemaster® opera-

tion problems. To adjust spring(s), only add

or remove a maximum of 3/10 of a turn

(three teeth of ratchet wheel) at a time.

Both sides need to be adjusted equally on

double spring doors.

PLACE VICE CLAMPS

BELOW BOTTOM SECTION

ON BOTH VERTICAL TRACK

PAWL KNOB IN LOWER

POSITION

PAWL KNOB IN UPPER

POSITION

LOWER POSITION UPPER POSITION

Cable Drum

No space between Ratchet

Pawl and Cable Drum

indicates engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEAT

H VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration, in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

RATCHET

WITH 5/8”

SOCKET

END BRACKET

3” EXTENSION

TorqueMaster® Plus Reset

Instructions Continued...

PAWL

INSTALLATION

Tools Needed:

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

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NOTE: Single spring applications require

no spring winding on left hand side.

Clamp a pair of vice clamps on the vertical

tracks just above the third roller on one

side and just below the third roller on the

other side. This will prevent the door from

raising or lowering while adjusting the

spring(s).

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 Add Spring Tension:

The ratchet wheel is made of 10 teeth. To

add spring tension, ensure the ratchet and

socket is set so that it will tighten counter

clockwise on the right hand side, and

clockwise on the left hand side. Place the

ratchet with 5/8” socket onto the wind-

ing shaft, pull down to add 3/10 of a turn.

Watch as three teeth of the ratchet wheel

pass over the ratchet pawl, creating three

“clicks”.

To Remove Spring Tension:

To remove spring tension, ensure the

ratchet and socket is set so that it will

tighten counter clockwise on the right

hand side and clockwise on the left hand

side. It is recommended that a regular 5/8”

wrench be used. Place the wrench onto

the winding shaft. Pull down on the wrench

to relieve pressure between the ratchet

pawl and the ratchet wheel. Push in on

the pawl to allow the three ratchet wheel

teeth to pass by the ratchet pawl, as you

carefully allow the wrench to be rotated

upward by the spring tension. Release the

pawl to allow ratchet pawl to engage with

the ratchet wheel.

Remove the vice clamps from the vertical

tracks, re-check doors balance and adjust

if necessary. When door is balanced and

adjusted properly, place the pawl knobs in

the active position (lower position).

TRACK

VICE CLAMPS

ATTACHED TO

INNER RAIL

OF TRACK

PLACE VICE CLAMPS

ABOVE 3RD ROLLER ON

BOTH VERTICAL TRACK

PAWL KNOB IN LOWER

POSITION

LOWER POSITION UPPER POSITION

Cable Drum

No space between Ratchet

Pawl and Cable Dr

um

indica

tes engagement

Cable Drum

Ratchet Pawl

ENGAGED SIDE VIEW

No space between

Ratchet Pawl and

Cable Drum

ENGAGED UNDERNEATH VIEW

Space between Ratchet Pawl

and Cable Drum

non-indicates engagement

Cable Drum

Ratchet Pawl

DISENGAGED SIDE VIEW

No space between

Ratchet Pawl and

DISENGAGED UNDERNEATH VIEW

UPPER POSITION LOWER POSITION

LOWER POSITION SIDE VIEW

UPPER POSITION SIDE VIEW

Ratchet Pawl in Lower Position

Ratchet Pawl in Upper Position

Use these Illustration, in conjunction with the Instructions on the other side of

this label.

WARNING

Rachet Bracket is under

EXTREME SPRING

TENSION.

To avoid possible severe or

fatal injury, DO NOT remove

fasteners from ratchet bracket

until spring(s) are fully

wnwound.

To safely unwind spring(s)

read

and follow the directions in the

installation instructions/owners

manual.

DO NOT REMOVE THIS TAG.

RATCHET

WITH 5/8”

SOCKET

END BRACKET

3” EXTENSION

TorqueMaster® Plus Reset

Instructions Continued...

PAWL KNOB IN UPPER

POSITION

PAWL

WARNING

39

Tools Needed:

Tools Needed:

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

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 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 9 on page 15.

❉

(4) 1/4”- 20 X 11/16”

SELF DRILLING SCREWS

1/8”

Power Drill

7/16” Socket

Driver

NOTE: When installing a DoorMasterTM

operator use the center bracket and

drive gear supplied with your operator

(located in DoorMasterTM package).

Slide the DoorMasterTM 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,

continue with Step 20 on page 24.

None

CENTER

BRACKET

BUSHING

ASSEMBLY

TORQUEMASTER® TUBE

A

DOORMASTERTM BRACKET/

DRIVE GEAR ASSEMBLY

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) 1/4” x

1-1/2” lag screws.

NOTE: After completing this step,

continue with Step 28 on page 31.

B

Tools Needed:

Power Drill

1/8” Drill Bit

7/16” Socket Driver

(2) 1/4” X 1-1/2”

HEX HEAD LAG

SCREWS

OPTIONAL INSTALLATION

❉DoorMasterTM Bracket

Tools Needed:

40

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Step Plate

Make one mark 1” (25 mm) up from

the center of bottom edge of the bottom

section and another mark 2-3/16” (56

mm) up from the first mark.

Note: Top of step plate can be no higher

then 6” from the bottom of the door.

Drill a 7/16” (11 mm) hole through the

section at each mark and insert the

outside step plate.Loosely fasten step

plate slide to base with (1) 1/4” - 20 x

5/8” carriage bolt and nut.

Align inside step plate holes and

fasten from inside using the #8 screws

provided. Install one #8 x 3/4” screw in

the bottom step plate hole. The screw in

the top hole varies with door models.

Use the screw size shown below for

your model door.

a) #8 x 3/4” screw for Model 9100

b) #8 x 1” screw Model 9400/9600

Tighten 1/4” - 20 carriage bolt and nut.

STEP PLATE OUTSIDE

STEP PLATE INSIDE

7/16” Drill Bit

Power Drill

7/16" Wrench

❉

(2) #8 SCREWS

ASSEMBLED

STEP PLATE

1/4” - 20 X 5/8”

CARRIAGE BOLT

HEX NUT

STEP PLATE

BASE

STEP PLATE

SLIDE

Tools Needed:

41

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Pull Rope

DO NOT INSTALL PULL ROPES

ON DOORS WITH ELECTRIC

OPERATORS. CHILDREN MAY

BECOME ENTANGLED IN THE

ROPE CAUSING SEVERE OR

FATAL INJURY.

Measure and mark the jamb

approximately 48” to 50” (1220 to 1270

mm) from floor on the right or left side

of jamb. Drill 1/8” pilot hole for No. 6

screw eye. Tie the pull rope to the No.

6 screw eye and to the bottom bracket

as shown.

NO. 6 SCEW EYE

PULL ROPE

BOTTOM BRACKET

PULL ROPE

WARNING

❉

Power Drill

1/8” Drill Bit

OPTIONAL INSTALLATIONOPTIONAL INSTALLATION

42

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DETERMINE THE WAYNE-DALTON

TRACK RADIUS BEING USED:

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 details on

how to assembly the curved and straight arm, as shown in

FIG. 2.4 through FIG. 2.5.

NOTE: Depending on your setup, you may or may not have to

cut straight arm to accomplish trolley settings, as shown in

FIG. 2.4 through FIG. 2.5.

Align hole in the appropriate arm with holes in operator

bracket tabs, as shown in FIG. 2.6. Insert 5/16” x 1-1/4”

clevis pin, making sure hole in clevis pin is outside of second

tab of operator bracket. Insert hairpin cotter into clevis pin

hole and spread hairpin cotter to ensure it will secure

assembly, as shown in FIG. 2.6.

❉

HORIZONTAL

TRACK

12” OR 15”

FIG. 2.5

STRAIGHT

ARM

CURVED

ARM

CUT STRAIGHT

ARM TO

ACCOMPLISH

TROLLEY

SETTING

FIG. 2.4

CUT STRAIGHT

ARM TO

ACCOMPLISH

TROLLEY

SETTING

CURVED

ARM

STRAIGHT

ARM

OPERATOR HOOK-UP CHART STANDARD LIFT FOR 15” RADIUS

OPERATOR MODELS TYPE OF ARM BEING USED REF. ILLUSTRATIONS

ABOVE

QUANTUM/CLASSIC CURVED / STRAIGHT FIG. 2.5

LINEAR STRAIGHT / CURVED FIG. 2.4

LIFTMASTER

(SEARS) CURVED / STRAIGHT FIG. 2.5

GENIE CURVED / STRAIGHT FIG. 2.5 OR FIG. 2.4

OPERATOR HOOK-UP CHART STANDARD LIFT FOR 12” RADIUS

OPERATOR MODELS TYPE OF ARM BEING USED REF. ILLUSTRATIONS

ABOVE

QUANTUM/CLASSIC CURVED / STRAIGHT FIG. 2.5

LINEAR STRAIGHT / CURVED FIG. 2.4

LIFTMASTER

(SEARS) CURVED / STRAIGHT FIG. 2.5

GENIE CURVED / STRAIGHT FIG. 2.5 OR FIG. 2.4

FIG. 2.2

TOP

SECTION

HIGH ARC

LEVEL

FIG. 2.3

FROM

STEP 12

HIGH ARC

LINE

TYPICAL 1/2” - 1” ABOVE HIGH ARC

VERTICAL

CENTER LINE

HEADER

TORQUEMASTER®

COUNTERBALANCE

FIG. 2.1

HAIRPIN

COTTER

OPERATOR

BRACKET

DOOR

ARM

5/16” X 1-1/4”

CLEVIS PIN

OPERATOR

BRACKET TABS

DOOR ARM

TOP VIEW

HAIRPIN COTTER

(OUTSIDE OF OPERATOR

BRACKET TAB)

OPERATOR BRACKET TABS

FIG. 2.6

43

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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

Trolley Installation for

Low Headroom

❉

HIGH ARC

LOW

HEADROOM

TRACK

TOP

SECTION

LEVEL

FIG. 3.1 FIG. 3.2

FIG. 3.3

STRAIGHT

ARM

FIG. 3.4

CURVED

ARM

CUT STRAIGHT

ARM TO

ACCOMPLISH

TROLLEY

SETTING

OPERATOR HOOK-UP CHART FOR LOW HEADROOM

OPERATOR MODELS

TYPE OF ARM BEING USED

PREFERRED

HOOKUP

REF. ILLUSTRA-

TIONS ABOVE

OPTIONAL

HOOKUP

REF. ILLUSTRATIONS

ABOVE

QUANTUM/CLASSIC CURVED /

STRAIGHT FIG. 3.4 STRAIGHT FIG. 3.3

LINEAR STRAIGHT FIG. 3.3 N/A N/A

LIFTMASTER

(SEARS)

CURVED /

STRAIGHT FIG. 3.4 STRAIGHT FIG. 3.3

GENIE CURVED /

STRAIGHT FIG. 3.4 STRAIGHT FIG. 3.3

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 arm to accomplish trolley settings, as shown in

FIG. 3.3 through FIG. 3.4.

Align hole in the appropriate arm with holes in operator

bracket tabs, as shown in FIG. 3.5. Insert 5/16” x 1-1/4”

clevis pin, making sure hole in clevis pin is outside of second

tab of operator bracket. Insert hairpin cotter into clevis pin

hole and spread hairpin cotter to ensure it will secure

assembly, as shown in FIG. 3.5.

FROM

STEP 12

HIGH ARC

LINE

TYPICAL 1/2” - 1”

ABOVE HIGH ARC

VERTICAL

CENTER LINE

HEADER

TORQUEMASTER®

COUNTERBALANCE

FIG. 5.2

HAIRPIN

COTTER

OPERATOR

BRACKET

DOOR

ARM

5/16” X 1-1/4”

CLEVIS PIN

OPERATOR

BRACKET TABS

DOOR ARM

TOP VIEW

HAIRPIN COTTER

(OUTSIDE OF OPERATOR

BRACKET TAB)

OPERATOR BRACKET TABS

FIG. 3.5

OPTIONAL INSTALLATION

Tools Needed:

44

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Trolley Operator

OPERATOR MUST BE TESTED AT TIME

OF INSTALLATION AND MONTHLY

THEREAFTER TO ENSURE THAT DOOR

REVERSES ON CONTACT WITH 2 X

4 BOARD LAID FLAT UNDER THE

DOOR. FAILURE TO PASS THIS TEST

REQUIRES IMMEDIATE ADJUSTMENTS

OR REPAIRS. FAILURE TO MAKE

ADJUSTMENTS, 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 PASS THIS TEST REQUIRES

IMMEDIATE ADJUSTMENTS OR REPAIRS.

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.

2. Mount operator to ceiling so that

1” to 1-1/2” (25 - 38 mm)

clearance is maintained between

trolley rail and top section when

door is fully open (trolley rail will

slope down towards rear).

3. Attach door arm to operator bracket

installed in Step 12.

4. Attach operator to a suitable

mounting surface (2” x 6”) lumber

minimum.

5. Attach operator to ceiling using

perforated angle.

IMPORTANT: ANGLE MUST BE

ATTACHED TO FRAMING MEMBER(S).

❉

WARNING SUITABLE MOUNTING

SURFACE (2” X 6”)

LUMBER MINIMUM

OPERATOR RAIL

HEADER

DOOR ARM TO

OPERATOR

BRACKET

OPERATOR

FRAMING MEMBERS

PERFORATED ANGLE

OPERATOR

RAIL

PERFORATED

ANGLE

45

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MAINTENANCE

While factory-applied finishes on steel 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, an

annual washing of the door is recommended.

A mild solution of detergent and water will aid in the removal of most dirt. The following solution mixture is recommended:

One cup of TideTM, or other common detergents, which contain less than 0.5% phosphate, dissolved into five gallons of warm water.

CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

1. 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.

2. Kerosene may be used to remove grease and oil. When using kerosene for cleaning purposes, make sure that you are familiar with

it’s properties, using it only in a well ventilated area away from any sources of sparks and/or fire.

3. DO NOT USE window cleaning fluids, scouring compounds, gritty cloths, gasoline, or solvents such

as alcohol, acetone, carbon tetrachloride, etc.

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. See the following paragraph if metal substrate is observed.

The exposed substrate 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. Follow 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.

NOTE: It is NOT recommend that you paint your door any dark color, this may lead to higher surface temperatures resulting in gaps

between the stiles and rails of your door section(s).

Cleaning

Painting

MAINTENANCE

46

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After surface has been properly prepared, it must be allowed to dry thoroughly, then coated immediately with a 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.

NOTES:

1. Repainting of finish painted steel doors cannot be warranted, as this condition is totally beyond the door manufacturer’s control.

2. If the finish painted steel door surface has a textured surface representing wood grain, stucco, etc., this step should not be

attempted as danger of exposing substrate is greatly increased.

3. Consult a professional coatings contractor if in doubt about any of the above directions.

4. 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.

Painting Continued....

47

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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 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 Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as his/her

primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or to installations on rental

property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the premises is sold), nor does it extend

benefits to any other person. As a result this warranty does NOT apply to any person who purchases this product from someone other than an authorized Wayne-Dalton

dealer or distributor.

The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its 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 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 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 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.

48

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business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com

Thank you for your purchase

Please Do Not Return This Product To The Store

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.