Waync Dalton 9100 Installation Instructions And Owner's Manual

Torquemaster single and double spring

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9100, 9400, AND 9600

TorqueMaster

- Single and Double Spring

Installation Instructions and Owner's Manual

Wayne-Dalton Corp.

P.O. Box 67

Mt. Hope, OH 44660

www.wayne-dalton.com

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 qualified door agency

do the installation or repairs.

Part No. 302868

REV 6 08/03/2009

Table of Contents

Summary of Contents for Waync Dalton 9100

Page 1 9100, 9400, AND 9600 TorqueMaster - Single and Double Spring ® Installation Instructions and Owner’s Manual IMPORTANT NOTICE! Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the Wayne-Dalton Corp. work. Instead, have a qualified door agency P.O.
Page 2: Table Of Contents
wARNINg READ ThESE Table of Contents INSTRUCTIONS CAREFUlly bEFORE Important safety Instructions ..........2 ATTEMPTINg INSTAllATION. IF Package Contents ..............3 Door section Identification ............4 IN qUESTION AbOUT ANy OF ThE Tools Required ................ 5 PROCEDURES, DO NOT PERFORM ThE Pre-Installation ..............5-10 wORk.
Page 3: Package Contents
(1) CENTER BRaCkET END BRaCkETs (as REquIRED) (as REquIRED) (as REquIRED) (as REquIRED) assEMBly 9100, 9600, 5120, 5140 TorqueMaster ® - Single and Double Spring Installation Instructions and Owner’s Manual IMPORTANT NOTICE! Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work.
Page 4: Door Section Identification
Door Section Identification WaRNING laBEl NOTE: This provides an alternative method Tools Needed: for identifying your door sections/stack position. TOP sECTION 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).
Page 5: Tools Required
Tools Required POWER DRIll RaTChET WRENCh PlIERs/WIRE CuTTERs TaPE MEasuRE 1/8”, 3/16” DRIll BITs GlOVEs PhIllIPs hEaD sCREWDRIVER flaT TIP sCREWDRIVER PENCIl NEEDlE NOsE PlIERs 7/16”, 1/2”, 9/16” 3/8”, 7/16”, 1/2”, 9/16” 7/16” sOCkET DRIVER safETy GlassEs WRENChEs sOCkETs sTEP laDDER haMMER (2) saW hORsEs VICE GRIPs...
Page 6 Torsion Spring Removal For Standard lift wARNINg Tools Needed: TORsION assEMBly faIluRE TO usE aPPROVED aPPROVED WINDING BaR approved WINDING BaRs CaN CausE Winding Bars sPRING ENERGy TO BE RElEasED suDDENly, REsulTING IN sEVERE 3/8” Wrench OR faTal INjuRy. wARNINg Vice Clamp COuNTERBalaNCE sPRING TENsION MusT BE RElIEVED...
Page 7 lOOsEN lOCk COuNTER TorqueMaster Spring Removal ® NuT 1/4 TuRN GEaR/ COVER a TorqueMaster spring system can be ® Tools Needed: identified by the end brackets. for 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...
Page 8 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.
Page 9: Removing The Old Door
REMOVE laG sCREW Extension Spring Removal fROM safETy CaBlE (If INsTallED). REPEaT fOR 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...
Page 10: Preparing The Opening
suITaBlE MOuNTING suRfaCE 2” x 6” Preparing the Opening luMBER MINIMuM hEaDER BOaRD 2” x 6” luMBER PREfERRED wARNINg faIluRE TO sECuREly Tools Needed: aTTaCh a suITaBlE Recommended MOuNTING PaD TO sTRuCTuRally sOuND DOOR tools from fRaMING COulD CausE sPRINGs TO VIOlENTly hEIGhT page 5 lEVEl hEaDER...
Page 11: Installation
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).
Page 12 fully aDjusTaBlE flaGaNGlE Attaching Fully Adjustable Flagangle to vertical Track 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 BOlTs...
Page 13 Installing q.I. Jamb brackets 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...
Page 14 bottom Section 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.
Page 15 Stacking Sections NOTE: for 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.
Page 16 (INsTallED IN ThE sTEP 12) 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”...
Page 17 Remove vice clamps. sCREWs FIg. 1.6 FIg. 1.5 NOTE: If you have a 9100 door, (2) of the 1/4” - 20 x 11/16” self-drilling screws (6) 1/4” - 14 x 5/8” used to attach the u-bar instead of (2) sElf-TaPPING 1/4”...
Page 18 DOOR WIDTh Top Section NaIl +3-3/8” TO 3-1/2” 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.
Page 19 1/4” - 20 x 9/16” flaGaNGlE Attaching Adjustable Flagangle laRGE hEaD to horizontal Track RIBBED TRaCk BOlTs 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”...
Page 20 TorqueMaster Spring Tube ® 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 ®...
Page 21 idrive Installation ® NOTE: see idrive Tools Needed: main installation and Tools Needed: ® owners manual for idrive parts. ® IMPORTANT: RIGhT aND lEfT haND Is alWays DETERMINED fROM INsIDE lEfT haND sIDE ThE GaRaGE lOOkING OuT. TORquEMasTER sPRING TuBE ®...
Page 22 TORquEMasTER ® COuNTERBalaNCE Cable Drum Installation sPRING TuBE GROOVE CaBlE Tools Needed: shake the TorqueMaster spring tube ® gently to extend the winding shafts out None about 5" on each side. for single WINDING spring applications, there will be no left sPlINEs shafT RIGhT haND...
Page 23 Drive gear Installation CaBlE WINDING DRuM shafT Tools Needed: Beginning with the right hand side, sPlINEs luBRICaTING lubricate entire circumference of the 36 lubricating Oil tooth worm gear with the lubricating oil 36 Tooth Worm provided. slide the 36th worm gear Gear 36 TOOTh onto the winding shaft splines until it...
Page 24 WINDING shafT INsIDE Counter Installation END BRaCkET COuNTER Tools Needed: Install the right side counter gear, with GEaR the missing tooth toward the outside MIssING None and away from the end bracket. Press TOOTh the counter gear onto the end bracket until snaps engage.
Page 25 Positioning Support bracket NOTE: see idrive main installation and ® 45 aNGlE aNTENNa Tools Needed: MOuNTING WIRE owners manual for idrive parts. ® suRfaCE Power Drill NOTE: idrive must be installed on a ® 1/8” Drill Bit solid mounting surface. 7/16”...
Page 26 Attaching Disconnect Cables s-hOOk Tools Needed: NOTE: see idrive main installation and ® DIsCONNECT owners manual for idrive parts. ® CaBlE Pliers hOlE IN RIGhT attach the loose disconnect cable END BRaCkET (located in opener hardware bag) to the opener with the “s” hook. Close both ends of the “s”...
Page 27 Attaching Disconnect handle NOTE: see idrive ® main installation and Tools Needed: owners manual for idrive parts. ® uPPER POsITION Phillips head screwdriver NOTE: Bring motor to the down position #6-20 x 1/2” by pulling the disconnect cable, insure Wire cutters sCREW opener disconnect teeth are engaged before installing disconnect handle.
Page 28 Securing Door for Spring winding wARNINg Tools Needed: Vice Clamp faIluRE TO PlaCE VICE ClaMPs ONTO VERTICal TRaCk CaN allOW DOOR TO RaIsE aND CausE sEVERE OR faTal INjuRy. PlaCE VICE Place vice clamps onto both vertical ClaMPs aBOVE tracks just above the third roller. This is 3RD ROllER to prevent the garage door from raising while winding counterbalance springs.
Page 29 winding bolt Rotation see chart in step 32 for proper spring Tools Needed: tension setting. Power Drill Beginning with the right hand side, ensure WINDING the cable is in the first groove of the cable 7/16" socket BOlT drum. apply light pressure to the canoe Driver clip on counter cover while winding springs.
Page 30 DRuM WRaP Drum wrap Installation Tools Needed: Drum wraps are identified as right and left hand. OuTsIDE None flaNGE To install, place the drum wrap over the cable drum and under the idrive ® disconnect cable (right hand side). align the outside flange over the outside edge CaBlE of the cable drum and push the drum...
Page 31 Rear Support Continued... sOuND fRaMING MEMBERs hex head lag screws and 5/16” bolts Tools Needed: 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).
Page 32: Optional Installations
� 1/8” Side lock Install the side lock on the second Tools Needed: section of the door. secure the lock to the section with (4) 1/4”- 20 x 11/16” Power Drill self drilling screws. square the lock 7/16” socket assembly with the door section and Driver align with the square hole in the vertical track.
Page 33: Step Plate
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...
Page 34: Trolley Instructions For Standard Lift
� DETERMINE ThE wAyNE-DAlTON Trolley Installation for lEVEl TRACk RADIUS bEINg USED: Standard lift hIGh aRC hORIzONTal Measure the curved ends of the horizontal track determine TRaCk if you have a 12” or 15” radius horizontal track, as shown in fIG. 2.1.
Page 35: Trolley Instructions For Low Headroom
� lEVEl Trolley Installation for TyPICal 1/2” - 1” hIGh aRC low headroom aBOVE hIGh aRC TORquEMasTER ® COuNTERBalaNCE hIGh aRC Determine center line of door. Mark vertical line at this lINE point, on the header wall. Raise the door slightly until the sECTION hEaDROOM top section reaches the highest point of travel (high...
Page 36: Trolley Operator
� Trolley Operator OPERaTOR RaIl suITaBlE MOuNTING wARNINg suRfaCE (2” x 6”) Tools Needed: luMBER MINIMuM 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 aDjusT OPERaTOR, If NECEssaRy, CaN REsulT IN sEVERE OR faTal INjuRy.
Page 37: Maintenance
Cleaning Cleaning your garage Door IMPORTANT: DO NOT usE a PREssuRE WashER ON yOuR GaRaGE DOOR! While factory-applied finishes on 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.
Page 38 Painting Continued..NOTES: 1. Repainting of finish painted steel doors cannot be warranted, as this condition is totally beyond the door manufacturer’s control. 2. Consult a professional coatings contractor if in doubt about any of the above directions. 3. 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.
Page 39: Warranty
Models 9100, 9400, 9600 subject to the terms and conditions contained in this lifetime limited Warranty, Wayne-Dalton Corp. (“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: 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.
Page 40: Dealer Locator Information
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;...

This manual is also suitable for:

9400 9600