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9100, 9400 and 9600 Series
®
TorqueMaster Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
Portland Source Plant
IMPORTANT NOTICE!
Read these instructions carefully before
attempting installation. If in question about
Wayne-Dalton Corp. any of the procedures, do not perform the
P.O. Box 67
work. Instead, have a trained door systems
Mt. Hope, OH 44660
technician do the installation or repairs.
www.wayne-dalton.com
Copyright 2009 Wayne-Dalton Corp. Part No. 32874
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waRNiNg Table of Contents Important Safety Instructions ............................................ 2 To avoiD PoSSible iNjuR y, ReaD TheSe Package Contents ............................................................. 3 iNSTRucTioNS caReFully beFoRe Door Section Identification ................................................ 4 Tools Required .................................................................. 5 aTTemPTiNg iNSTalla TioN. iF iN queSTioN abouT aNy oF The PRoceDuReS, Do No T Re
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NoTe: DEPENDING ON THE DOOR MODEL, SOME PARTS LISTED WILL NOT bE SUPPLIED If NOT NECESSARY . REAR Package contents SUPPORTS MAY OR MAY NOT bE INCLUDED WITH YOUR DOOR. (2) HORIzONTAL TRACkS RH/LH (2) fULLY ADjUSTAbLE RH/LH fLAGANGLES DOOR SECTIONS (AS REqUIRED) ® (1) TORqUEMASTER SPRING TUbE END bRACkETS LH/RH (2) DRUM WRAPS (1) CENTER bRACkET (1) LOOSE WINDING SHAfT RIGHT AND LEfT CAbLE LH/RH ASSEMbLY (SINGLE SPRING ONLY) DRUM ASSEMbLIES (2) VERTICAL RH/LH TRACkS (2) TOP bRACkET (2) TOP bRAC
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Door Section identification Hinges are always pre-attached at the top Tools Needed: WARNING LAbEL of each section (except top section) and the hinges are stamped for identification, #1, #2, #3, and #4 (#4 only on five TOP SECTION #4 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 h
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Tools Required 5/8”, 1/2”, 7/16” PENCIL RATCHET WRENCH VICE GRIPS GLOVES 1/2”, 7/16” SOCkET LEVEL & 9/16” SOCkET DRIVER 3/16”, 7/16” & 1/8” SAfETY GLASSES 1/2, 7/16” & 9/16” HAMMER 3” EXTENSION fLAT TIP SCREWDRIVER DRILL bITS WRENCHES TAPE MEASURE VICE CLAMPS HACkSAW SAWHORSE PHILLIPS HEAD PLIERS/CUTTERS POWER DRILL SCREWDRIVER STEP LADDER Removing an existing Door Counterbalance spring tension must always be released before any attempt is made to start removing an existing door. waRNiNg A P
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SUITAbLE MOUNTING SURf ACE 2” X 6” Preparing the opening LUMbER MINIMUM HEADER bOARD P1 2” X 6” LUMbER PREfERRED fAILURE TO Tools Needed: waRNiNg SECURELY ATTACH A Recommended SUITAbLE MOUNTING PAD TO STRUCTURALLY tools from DOOR HEIGHT SOUND fRAMING COULD CAUSE SPRINGS TO LEVEL HEADER page 5 VIOLENTLY PULL MOUNTING PAD fROM WALL, RESULTING IN SEVERE OR f ATAL INjURY. PLUMb jAMbS If you just removed your existing door or you are installing a new door, complete all steps in PREPARING
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installation begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb and the header level. Side clearance, from edge of door to wall, must be minimum of 3-1/2” (89 mm) on each side. imPoRTaNT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MUST bE USED WHEN INSTALLING CENTER bEARING bRACkETS, END bRACkETS, jAMb bRACkETS, OPERATOR MOUNTING/SUPPORT bRACkETS AND DISCONNECT bRACkETS ON TREATED LUMbER (PRESERVATIVE-TREATED). STAINL
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cutting vertical Track and installing q.i. jamb brackets continued Tools Needed: Tape Measure Hacksaw Power Drill 5/16” Drill bit vertical Track cutting chart Vertical Track Cut Length Horizontal Vertical Track Cut Length Track Radius 10”, 12” Door Height Minus 10” jamb bRackeT ScheDule 14” Door Height Minus 8” Cut vertical 1ST SeT 2ND SeT 3RD SeT track here DooR 3-1/2” LHR Door Height Minus 15” jamb jamb jamb heighT PoSiTioN PoSiTioN PoSiTioN 6-1/2” LHR Door Height Minus 12” bkT bkT bkT 6’
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® LEfT HAND TORqUEMASTER PLUS COUNTER bALANCE DRUM #1 END HINGE counterbalance Drums (HINGE TUbE) 3 bOTTOM SECTION Tools Needed: imPoRTaNT: RIGHT AND LEfT HAND IS ALWAYS DETERMINED fROM INSIDE None ROLLERS THE bUILDING LOOkING OUT. NoTe: for door section identification see page 4. COUNTERbALANCE CAbLE ® TorqueMaster Plus counterbalance drums are marked right and left hand. Uncoil the counterbalance cables and make sure you place the right hand cable loop on the right hand milford pin
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fLAGANGLE vertical Track 5 Tools Needed: imPoRTaNT: THE TOPS Of THE 5/16” X 2” LAG VERTICAL TRACkS MUST bE LEVEL SCREWS 3/16” Drill bit fROM SIDE TO SIDE. If THE bOTTOM SECTION WAS SHIMMED TO LEVEL Power Drill IT, THE VERTICAL TRACk ON THE SHIMMED SIDE MUST bE RAISED THE CAbLE 7/16” Socket HEIGHT Of THE SHIM. Driver Position the left hand vertical track Tape Measure assembly over the rollers of the bottom VERTICAL section. Make sure the counterbalance TRACk Level ASSEMbLY cable is l
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Stacking Sections 6 Tools Needed: NoTe: for door section identification see page 4. Power Drill NoTe: Make sure hinge leafs are 7/16” Socket flipped down, when stacking another Driver section on top. Place rollers in hinge tubes of the second section (lock section). With assistance, lift the second section LOCk SECTION and guide rollers into the vertical tracks. Maintaining section vertical alignment; starting with the center hinge first, flip up the hinge leaf, and hold it tight aga
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Top brackets 7 1ST SET (10” & 12” RADIUS) NoTe: The top brackets may be pre- Tools Needed: TOP SECTION assembled in some cases. Power Drill (4) 1/4” - 14 x 5/8” 2ND SET SELf TAPPING (14” RADIUS) To install the L-shaped top brackets, 7/16” Socket SCREWS align the top holes in the top bracket Driver base with: TOP bRACkET bASE a) the second set of holes in the endstile for 14” radius track. b) the first set of holes in the endstile for (2) 1/4”- 20 x 5/8” 10” & 12” radius track. CARRIAGE bOLT
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6” 6” u-bar 8 U-bAR Tools Needed: NoTe: If you have a model 9400/9600 Series door with windows in the top Power Drill section or 9100 Sonoma (8’ high), skip this step and complete step 9. 7/16” Socket OPERATOR Driver bRACkET 1/4”-14 X 5/8” SELf NoTe: Model 9100 Series door over 13’ (INSTALLED IN TAPPING SCREWS wide require a 3” U-bar (supplied). STEP 10) (4) 1/4”- 20 X 11/16” TOP DOOR SECTION SELf DRILLING SCREWS Place the 3” U-bar over the top rib. fasten each end of the U-bar to the
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U-bAR U-bAR U-bAR TOP CENTER operator bracket fLANGE OPERATOR LINE 10 fRONT bRACkET NoTe: Operator bracket must be mounted Tools Needed: and secured prior to installing top section. Power Drill bOTTOM imPoRTaNT: WHEN CONNECTING A U-bAR fLANGE TROLLEY TYPE GARAGE DOOR 7/16” Socket OPENER TO THIS DOOR, A WAYNE-DALTON Driver OPENER/TROLLEY bRACkET MUST bE SECURELY ATTACHED TO THE TOP Vice Clamps SECTION Of THE DOOR, ALONG WITH ANY U-bARS PROVIDED WITH TOP SECTION Phillips Head TOP WITH
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Top Section 11 Place the top section in the opening Tools Needed: DOOR WIDTH and vertically align with lower sections. +3-3/8” TO 3-1/2” Hammer Temporarily secure the top section by Tape Measure driving a nail in the header near the center of the door and bending it over Power Drill the top section. 7/16” Socket Now flip up hinge leaf against section, Driver fastening center hinges first, and end 7/16” Wrench hinges last. (Refer to Step 6). When installing a door with ® Torquemaster Plu
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attaching horizontal Track to Fully adjustable Flagangle 12 Tools Needed: To install horizontal track, place the curved end over the top roller. Align fLAGANGLE 9/16” Socket the bottom of the horizontal track with the vertical track. Hand tighten the 7/16” Socket horizontal track to the flagangle with (2) 1/4”- 20 x 5/8” carriage bolts and (2) Ratchet Wrench 1/4”- 20 flange hex nuts. HORIzONTAL TRACk 9/16” Wrench waRNiNg Level DO NOT RAISE DOOR UNTIL Hammer HORIzONTAL TRACkS ARE SE CURED
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adjusting Top brackets HORIzONTAL 13 TRACk With horizontal tracks installed, you can Tools Needed: now adjust the top brackets. Vertically 7/16” Wrench align the top section of the door with the lower sections. Once aligned, position Step Ladder the top bracket slide, out against the horizontal track. Maintaining the slide’s position, tighten the (2) 1/4”- 20 flange hex nuts to secure the top bracket slide to the top bracket base. TOP ROLLER TOP bRACkET SLIDE TOP (2) 1/4”- 20 SECTIO
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® Torquemaster Spring Tube 14 ® Tools Needed: TorqueMaster springs come lubricated and pre-assembled inside the None ® TorqueMaster spring tube. To install, ® lay the TorqueMaster spring tube on the floor (inside garage) in front of the door with the labeled end to the left. ® TORqUEMASTER SPRING TUbE LAbELED END CENTER center bracket bushing bRACkET 15 ASSEMbLY ® Tools Needed: NoTe: If you are installing the opener with your garage door, skip this step ® None and go to your idrive
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Drum wraps 16 imPoRTaNT: RIGHT AND LEfT HAND Tools Needed: IS ALWAYS DETERMINED fROM INSIDE None THE GARAGE LOOkING OUT. RIGHT HAND DRUM WRAP Drum wraps are identified as right and left. Slide the left hand drum wrap over the ® left side of the TorqueMaster spring LEfT HAND DRUM WRAP tube assembly with the tabs facing left. Continue sliding the left hand drum wrap towards the center of the ® TorqueMaster spring tube assembly. Repeat for opposite side. LEfT HAND DRUM WRAP ® TORqUEMASTER
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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. Use these Illustration, in conjunction with the Instructions on the other side of this label. ENGAGED SIDE VIEW Cable Drum ENGAGED UNDERNEATH VIEW Ratchet Pawl No space between Ratchet
