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9100, 9400, 9600
Torsion Spring
Installation Instructions and Owner’s Manual
Portland Source Plant
IMPORTANT NOTICE!
Read these instructions carefully before
attempting installation. If in question about
Wayne-Dalton Corp. any of the procedures, do not perform the
P.O. Box 67
work. Instead, have a qualified door agency
Mt. Hope, OH 44660
do the installation or repairs.
www.wayne-dalton.com
© Copyright 2009 Wayne-Dalton Corp. Part No. 290771 REV4 08/03/2009
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waRNiNg Table of Contents Important Safety Instructions ............................................ 2 ReaD TheSe iNSTR ucTioNS Package Contents ..........................................................3-4 caReFully beFoRe a TTemPTiNg Door Section Identification ................................................ 4 Tools Required .................................................................. 5 iNSTalla TioN. iF iN queSTioN abouT aNy oF The PRoceDuReS, Do Pre-Installation ..
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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) END bEARING bRACkETS RH/LH DOOR SECTIONS (AS REqUIRED) (2) HORIzONTAL TRACkS WITH ATTACHED HORIzONTAL ANGLE RH/LH (2) SPRINGS WITH CONES RH/LH TORSION TUbE WEATHER SEAL & q.I. jAMb bRACkETS (2) CAbLE DRUMS (1) OPERATOR ROLLERS RH/LH bRACkET (AS REqUIRED) (AS REqUIRED) NAILS (If INCLUDED) (2) fULLY ADjUSTAbLE (2) VERTICAL (
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Door Section identification NoTe: This provides an alternative method Tools Needed: WARNING LAbEL for identifying your door sections/stack position. TOP SECTION #4 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 INTERMEDIATE II SECTION determined by #1 being the
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Tools Required 1/8”, 7/16”, 3/16” PENCIL POWER DRILL RATCHET WRENCH TAPE MEASURE LEVEL DRILL bITS APPROVED WINDING bARS PHILLIPS HEAD SCREWDRIVER fLAT TIP SCREWDRIVER GLOVES 1/4” TORx bIT 7/16”, 1/2”, 3/8”, 9/16” 7/16”, 1/2”, 9/16” 7/16” SOCkET DRIVER SAfETY GLASSES SOCkETS WRENCHES STEP LADDER HAMMER SAW HORSES (PAIR) VICE GRIPS VICE CLAMPS 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 AGENC
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Torsion Spring Removal P1 For Standard lift Tools Needed: waRNiNg TORSION SPRING ASSEMbLY Recommended fAILURE TO USE APPROVED tools from WINDING bARS CAN CAUSE SPRING page 5 ENERGY TO bE RELEASED SUDDENLY, RESULTING IN SEVERE OR f ATAL INjURY. waRNiNg COUNTERbALANCE SPRING TENSION MUST bE RELIEVED bEfORE REMOVING ANY WINDING CONE HARDWARE. A POWERfUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR f ATAL INjURY. Do not release the torsion spring tension unless you are a qu
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LOOSEN LOCk COUNTER ® Torquemaster Spring Removal NUT 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 bracket will always have a drive gear, Recommended END bRACkET counter gear, counter cover, and a winding tools from 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 plugged. f
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® Torquemaster Spring Removal continued... If the counterbalance cable is still taut and Tools Needed: ® the TorqueMaster Spring Tube is difficult to rotate, that is an indication that spring Recommended tension still exists on the left hand spring. tools from Repeat Steps 1 and 2 for releasing spring page 5 tension on the left hand side. Step 4: Using a flat tip screwdriver, pry REMOVE TOP the counter gear and counter cover LAG SCREW from the right hand end bracket (f ig. 4 on previ
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REMOVE LAG SCREW fROM SAfETY CAbLE (If extension Spring Removal INSTALLED). REPEAT 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 SURf ACE 2” x 6” Preparing the opening LUMbER MINIMUM P5 HEADER bOARD 2” x 6” LUMbER fAILURE TO RECOMMENDED Tools Needed: waRNiNg SECURELY ATTACH A Recommended SUITAbLE MOUNTING PAD TO STRUCTURALLY DOOR HEIGHT tools from SOUND fRAMING COULD CAUSE SPRINGS TO page 5 LEVEL HEADER 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 PREPARIN
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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 PT 2000 COATED LAG SCREWS MUST bE USED WHEN INSTALLING CENTER bEARING bRACkETS, END bRACkETS, jAMb bRACkETS, OPERATOR MOUNTING/SUPPORT bRACkETS AND DISCONNECT bRACkETS ON TREATED LUMbER (PRESERVATIVE-TREATED). STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UNTREATED LUMb
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installing q.i. Jamb brackets 2 Measure the length of the vertical Tools Needed: tracks. Using the jamb bracket schedule, None determine the placement of the jamb brackets for your door height and track type. 3RD SET HOLES To install the jamb brackets, align the twistlock tab on the quick install jamb bracket with the quick install feature LEf T SIDE SHOWN in the track and turn the bracket perpendicular to the track so the mounting flange is toward the back (flat) leg of the track. 2
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COUNTERbALANCE CAbLE Drums HINGE TUbE 3 bOTTOM SECTION Tools Needed: imPoRTaNT: RIGHT AND LEfT HAND IS ALWAYS DETERMINED fROM INSIDE None THE bUILDING LOOkING OUT. ROLLERS NoTe: f or door section identification see page 4. Uncoil the counterbalance cables and make sure you place the right hand cable loop on the right hand milford pin and place the left hand cable loop on the left hand milford pin. Insert a roller into bottom bracket of the bOTTOM bRACkET MILfORD PIN bottom section and i
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fLAGANGLE vertical Track 5 5/16” x 2” LAG SCREWS Tools Needed: imPoRTaNT: THE TOPS Of THE VERTICAL TRACkS MUST bE LEVEL 3/16” Drill bit fROM SIDE TO SIDE. If THE bOTTOM SECTION WAS SHIMMED TO LEVEL IT. Power Drill THE VERTICAL TRACk ON THE SHIMMED SIDE, MUST bE RAISED THE HEIGHT Of 7/16” Socket THE SHIM. Driver Position the left hand vertical track Tape Measure assembly over the rollers of the bottom VERTICAL Level section. Make sure the counterbalance TRACk cable is located between
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Stacking Sections 6 LOCk SECTION Tools Needed: NoTe: f or 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 and guide rollers into the vertical tracks. keep sections vertically aligned and fasten hinges to connect the sections using 1/4”- 14 x 5/8” self tapping screws. Rep
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1ST Top brackets SET 7 2ND SET NoTe: This step may be pre-assembled Tools Needed: on some models. Power Drill 3RD SET To install the L-shaped top brackets, 7/16” Socket align the top holes in the top bracket Driver base with: a) the second set of holes in the endstile for 14” radius track. b) the first set of holes in the endstile for 10” & 12” radius track. 1ST SET (10” & 12” RADIUS) f asten using (4) 1/4”- 14 x 5/8” self tapping screws. TOP SECTION (4) 1/4” - 14 x 5/8” 2ND SET Secur
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6” 6” u-bar 8 Tools Needed: NoTe: If you have a model 9600 Series door with windows in the top section or Power Drill 9100 Sonoma (8’ high), skip this step and complete step 9. 7/16” Socket OPERATOR Driver bRACkET U-bAR NoTe: Model 9100 Series door over 13’ (INSTALLED IN 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. f asten each end of the u-bar to the endstile with (2) 1/4”- 20 x 11/16” sel
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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 TM NoTe: If an idrive operator is to be U-bAR fLANGE installed, the operator bracket is not 7/16” Socket required to be installed. Driver imPoRTaNT: WHEN INSTALLING A Vice Clamps TROLLEY TYPE OPERATOR ON 9100, 9400 AND 9600 SERIES DOORS, A WAYNE- TOP SECTION Phillips Head TOP DALTON T
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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 Driver Now flip up hinge leaf against section, fastening center hinges first, and end hinges last. (Refer to Step 6). When installing a door with a torsion counterbalance system
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HORIzONTAL attaching horizontal Track to adjustable fLAGANGLE TRACk Flagangle 12 Tools Needed: To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track 9/16” Socket with the vertical track. Hand tighten the horizontal track to the flagangle with (2) 1/4”- 20 x 5/8” carriage 7/16” Socket (2) 1/4”- 20 x 5/8” bolts and (2) 1/4”- 20 flange hex nuts. CARRIAGE bOLTS Ratchet Wrench Level the horizontal track assembly and bolt the 9/16” Wren
