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9100, 9400, AND 9600
®
TorqueMaster - 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 2010 Wayne-Dalton, a Division of Overhead Do
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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 OR May NOT BE INCluDED WITH yOuR DOOR. DOOR sECTIONs (as REquIRED) (2) TOP BRaCkET slIDE ® (1)TORquEMasTER sPRING TuBE (2) HORIzONTal TRaCk RH/lH (2) quICk INsT all RH/lH (2) fully aDjusT aBlE RH/lH flaGaNGlE (as REquIRED) flaGaNGlE (as REquIRED) (2) HORIzONTal aNGlE RIGHT aND lEfT CaBlE ® asyMMETRICal u-BaR u-BaR IDRIVE OPERaTOR (21-15/16” OR 80”) DRuM assEMBlIEs
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Door Section Identification WaRNING laBEl NOTE: This provides an alternative method Tools Needed: for identifying your door sections/stack 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 only on five WaRNING laBEl section doors). see view below. The stamp identifies the stacking sequence of the section. The sequence is always determined by #1 being the bottom IN
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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 assEMBly aPPROVED WINDING BaR 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 page 5 sPRING RElEasING IT’s ENERGy suDDENly CaN CausE sEVERE OR fa Tal INjuR y
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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... spring tube should be free to rotate in Tools Needed: either direction. If the counterbalance ® cable is still taut and the TorqueMaster Recommended spring tube is difficult to rotate, that is an tools from indication that spring tension still exists page 5 on the left hand spring. Repeat steps 1 and 2 for releasing spring tension on the REMOVE TOP left hand side. laG sCREW Step 4: using a flat tip screwdriver, pry Fig. 5 the counter gear and
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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 f aIluRE TO sECuREly Tools Needed: WARNINg aTTaCH a suIT aBlE Recommended MOuNTING PaD TO sTRuCTuRally sOuND DOOR tools from fRaMING COulD CausE sPRINGs TO VIOlENTly HEIGHT lEVEl HEaDER page 5 Pull MOuNTING P aD fROM Wall, REsul TING IN sEVERE OR fa Tal INjuR y. PluMB jaMBs If you just removed your existing door or you are installing a new door, complete all steps in PREPa
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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 Flagangle to vertical Track 2 Tools Needed: NOTE: If quick install flagangle 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 (or stud plate if flaNGE HEx included) and (2) 1/4” - 20 flange hex NuTs nuts. secure the f
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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 INsTallING a Driver TROllEy TyPE OPERaTOR ON 9100, Vice Clamps 9400, aND 9600 sERIEs DOORs, a Phillips Head WayNE-Dal TON TROllEy BRaCkET TOP screwdriver MusT BE sECuREly a TTaCHED TO s
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flaGaNGlE flaGaNGlE DOOR WIDTH Top Section NaIl +3-3/8” TO 3-1/2” 13 Tools Needed: Place the top section in the opening and vertically align with lower sections. Hammer Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section. Now flip up hinge leaf, hold tight against section, and fasten center hinges first, and end hinges last. (Refer to step 8). When installing a door with a ® TorqueMaster counterbalance system
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1/4” - 20 x 9/16” flaGaNGlE Attaching Adjustable Flagangle laRGE HEaD to horizontal Track RIBBED TRaCk 15 BOl Ts NOTE: If quick install flagangles were Tools Needed: installed in step 14, skip this step and continue with step 16. If not, complete this 7/16” socket step. To install horizontal track, place the curved 9/16” socket end over the top roller. align the bottom of Ratchet Wrench the horizontal track with the vertical track. Hand tighten the horizontal track to the 9/16” Wrench
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® TorqueMaster Spring Tube 17 ® 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 18 assEMBly ® Tools Needed: NOTE: If you are installing the idrive opener on your garage door, skip this step and continue with step 19
