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9100, 9400, AND 9600
®
TorqueMaster Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
IMPORTANT NOTICE!
Read these instructions carefully before attempting
Wayne-Dalton, a Division of
installation. If in question about any of the proce-
Overhead Door Corporation
dures, do not perform the work. Instead, have a
P.O. Box 67, Mt. Hope, OH 44660
qualified door agency do the installation or repairs.
www.Wayne-Dalton.com
©Copyright 2012 Wayne-Dalton, a Division of Overhe
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WARNINg READ ThESE Table of Contents Important safety Instructions .................................................. 2 INSTRUCTIONS CAREFUlly bEFORE Package Contents ................................................................... 3 ATTEMPTINg INSTAllATION. IF Door section Identification ...................................................... 4 Tools Required ........................................................................ 5 IN qUE
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NOTE: DEPENDING ON THE DOOR MODEl, sOME P aRTs lIsTED WIll NOT BE suPPlIED If NOT Package Contents NECEssaR y. REaR suPPORTs May NOT BE INCluDED WITH yOuR DOOR. DOOR sECTIONs (as REquIRED) (1) CENTER BRaCkET ® assEMBly (1)TORquEMasTER sPRING TuBE (2) quICk INsT all RH/lH (2) fully aDjusT aBlE RH/lH (2) HORIzONTal TRaCks RH/lH flaGaNGlEs (as REquIRED) flaGaNGlEs (as REquIRED) (2) HORIzONTal aNGlEs CaBlE DR uM assEMBlIEs ® IDRIVE OPERaTOR u-BaR (21-15/16” OR 80”) (1) RIGHT & (1) lEfT (sOlD sEP a
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Door Section Identification WaRNING laBEl NOTE: This provides an alternative Tools Needed: method for identifying your door sections/stacking position. TOP sECTION #3 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 WaRNING laBEl 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 INTERME
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Tools Required POWER DRIll RaTCHET WRENCH PlIERs/WIRE CuTTERs TaPE MEasuRE 1/8”, 3/16” DRIll BITs PHIllIPs HEaD sCREWDRIVER fla T TIP sCREWDRIVER PENCIl NEEDlE NOsE PlIERs GlOVEs 3/8”, 7/16”, 1/2”, 9/16” 7/16”, 1/2”, 9/16” 7/16” sOCkET DRIVER safETy GlassEs sOCkETs WRENCHEs sTEP laDDER HaMMER VICE GRIPs VICE ClaMPs (2) sa W HORsEs Removing An Old Door WARNINg If yOuR COuNTERBalaNCE sysTEM Is OTHER THaN THOsE MENTIONED, DO NOT aTTEMPT TO WORk ON IT, BuT HaVE a qualIfIED DOOR aGENCy PERfORM THE
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Torsion Spring Removal P1 For Standard lift Tools Needed: WARNINg TORsION sPRING assEMBly approved f aIluRE TO usE aPPROVED Winding Bars WINDING BaRs CaN CausE sPRING ENERGy TO BE RElEasED suDDENly, REsul TING IN sEVERE 3/8” Wrench OR fa Tal INjuR y. WARNINg Vice Clamp COuNTERBalaNCE sPRING TENsION MusT BE RElIEVED Recommended BEfORE REMOVING aNy WINDING CONE tools from HaRDWaRE. a POWERful sPRING page 5 RElEasING IT’s ENERGy suDDENly CaN CausE sEVERE OR fa Tal INjuR y. Do not relea
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lOOsEN lOCk COuNTER ® TorqueMaster Spring Removal NuT 1/4 TuRN GEaR/ COVER P2 ® a TorqueMaster spring system can be Tools Needed: identified by the end brackets. f or single spring applications, the right hand end RIGHT HaND Recommended bracket will always have a drive gear, END BRaCkET tools from counter gear, counter cover, and a winding bolt head. The left hand end bracket will page 5 have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be p
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® TorqueMaster Spring Removal continued... should be free to rotate in either direction. Tools Needed: If the counterbalance cable is still taut and ® the TorqueMaster spring Tube is difficult Recommended to rotate, that is an indication that spring tools from tension still exists on the left hand spring. page 5 Repeat steps 1 and 2 for releasing spring tension on the left hand side. REMOVE TOP Step 4: using a flat tip screwdriver, laG sCREW pry the counter gear and counter cover Fig.
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REMOVE laG sCREW fROM safETy CaBlE (If Extension Spring Removal INsTallED). REPEa T fOR P3 OPPOsITE sIDE. Step 1: Raise the door to the fully open Tools Needed: position and place vice clamps to the back Recommended legs of both vertical tracks, below the tools from bottom rollers to prevent the door from page 5 falling. By opening the door you release most of the spring tension. Carefully BOTTOM sECTION unfasten the s-hook from the horizontal (DOOR OPEN) angle. Remove cable, sheave and
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suITaBlE MOuNTING suRfaCE 2” x 6” Preparing the Opening luMBER MINIMuM HEaDER BOaRD P5 2” x 6” luMBER PREfERRED Tools Needed: WARNINg f aIluRE TO sECuREly Recommended aTTaCH a suIT aBlE MOuNTING P aD TO DOOR tools from sTRuCTuRally sOuND fRaMING COulD CausE HEIGHT lEVEl HEaDER page 5 sPRINGs TO VIOlENTly Pull MOuNTING P aD fROM Wall, REsul TING IN sEVERE OR fa Tal PluMB jaMBs INjuR y. If you just removed your existing door or you are installing a new door, complete all steps in PREP
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Installation IMPORTANT: REaD INsTR uCTIONs TITlED “P4” “REMOVING THE OlD DOOR” ON P aGE 9 aND “P5” “PREPaRING THE OPENING” ON PaGE 10 BEfORE a TTEMPTING DOOR INsTalla TION. IMPORTANT: sTaINlEss sTEEl OR PT2000 COa TED laG sCREWs MusT BE usED WHEN INsTallING CENTER BEaRING BRaCkETs, END BRaCkETs, jaMB BRaCkETs, OPERa TOR MOuNTING/suPPORT BRaCkETs aND DIsCONNECT BRaCkETs ON TREaTED luMBER (PREsERVaTIVE-TREaTED). sTaINlEss sTEEl laG sCREWs aRE NOT NECEssaR y WHEN INsTallING PRODuCTs ON uN-TREa T
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fully aDjusT aBlE flaGaNGlE Attaching Fully Adjustable Flagangles to vertical Track 2 Tools Needed: NOTE: If quick install flagangles was installed in step 1, skip this step and None continue with step 3. If not, complete this step. 1/4” - 20 x 9/16” laRGE HEaD RIBBED Hand tighten the flagangle to the vertical TRaCk BOl Ts track using (2) 1/4” - 20 x 9/16” large 1/4”- 20 head ribbed track bolts and (2) 1/4” - 20 flaNGE HEx flange hex nuts. Repeat for other side. NuTs secure the flang
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Installing q.I. Jamb brackets 4 Measure the length of the vertical tracks. Tools Needed: using the jamb bracket schedule, None 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. l Ef T sIDE sHOWN RIGHT sIDE sHOWN
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bottom Section 6 Tools Needed: Before installing the bottom section, the weather seal (may not be included) level 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. WEaTHER sEal DOOR OPENING lEVEl WOODEN sHIMs (If NECEssaR y) CaBlE DR uM VERTICal TRaCk vertical Track flaGaNGlE BOTTOM sECTION 7 Tools Needed: IMPORTANT: THE TOPs Of THE 5/16” x 1-5/8” VERTICal TRaC
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Stacking Sections 8 NOTE: f or door section identification see Tools Needed: page 4. Power Drill NOTE: Make sure hinges are flipped down, 7/16” socket when stacking another section on top. Driver 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
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6” OPERaTOR BRaCkET 6” U-bar (INsTallED IN THE sTEP 12) 10 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 7/16” socket this step and complete step 11. Driver (2) 1/4”-20 x 5/8” sElf TaPPING NOTE: Model 9100 series door over 13’ (2) saw Horses u-BaR sCREWs wide require a 3” u-Bar (supplied). (2) 1/4”-20 x 11/16” sElf DRIllING sCREWs Place the 3” u-bar over the top rib. f asten each end of the u-bar
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u-BaR u-BaR u-BaR alIGN CENTER Of BOTH TaBs WITH CENTER lINE Of TOP sECTION MalE P aRT Of Operator bracket OPERaTOR TOP sECTION 12 BRaCkET Tools Needed: NOTE: Operator bracket must be mounted and secured prior to installing Power Drill top section. OPERaTOR 7/16” socket u-BaR BRaCkET IMPORTANT: WHEN CONNECTING a Driver TROllEy TyPE GaRaGE DOOR OPENER Vice Clamps TO THIs DOOR, a WayNE-Dal TON Phillips Head OPENER/TROllEy BRaCkET MusT TOP screwdriver BE sECuREly aTTaCHED TO THE TOP s
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DOOR WIDTH Top Section +3-3/8” TO 3-1/2” 13 Tools Needed: Place the top section in the opening. Temporarily secure the top section Hammer 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
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flaGaNGlE flaGaNGlE Attaching horizontal Track to quick Install Flagangle 14 NOTE: If you have fully adjustable Tools Needed: flagangle, skip this step and complete 9/16” socket step 15. kEy slOT Ratchet Wrench HORIzONTal To install horizontal track, place the TRaCk 9/16” Wrench curved end over the top roller. align level key slot of the horizontal track with the quICk quick install tab of the flagangle. Push INsTall TaB curved portion of horizontal track down to lock in place. VERTI
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Attaching horizontal Track to Adjustable Flagangle 15 flaGaNGlE NOTE: If quick install flagangles were Tools Needed: installed in step 14, skip this step and 7/16” socket continue with step 16. If not, complete this step. 9/16” socket Ratchet Wrench To install horizontal track, place the 9/16” Wrench curved end over the top roller. align the bottom of the horizontal track with the level vertical track. Hand tighten the horizontal flat Tip track to the flagangle with (2) 1/4” - 20 x s
