9100, 9400, AND 9600 TorqueMaster® Plus - Single and Double Spring Installation Instructions and Owner’s Manual Wayne-Dalton, a Division of Overhead Door Corporation P.O. Box 67, Mt. Hope, OH 44660 www.Wayne-Dalton.com ©Copyright 2012 Wayne-Dalton, a Division of Overhead Door Corporation IMPORTANT NOTICE! Read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work.
Table of Contents Important Safety Instructions................................................... 2 Package Contents.................................................................... 3 Door Section Identification....................................................... 4 Tools Required......................................................................... 5 Pre-Installation...................................................................5-10 Removing The Old Door........................................
NOTE: Depending on the door model, some parts listed will not be supplied if not necessary. rear supports may not be included with your door. Package Contents DOOR SectionS (as required) (1) Center Bracket assembly (1)TorqueMaster® Spring tube (2) Quick Install RH/LH (2) Fully Adjustable RH/LH Flagangles (as required) Flagangles (as required) idrive® Operator (sold separately) U-Bar (if required) asymmetrical u-bar (if required) (2) Horizontal Tracks RH/LH Q.I.
Door Section Identification Tools Needed: Warning label NOTE: This provides an alternative method for identifying your door sections/stacking position. 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.
Power Drill Ratchet Wrench Pliers/Wire Cutters Tape Measure 1/8”, 3/16” Drill Bits Phillips Head Screwdriver Flat Tip Screwdriver Pencil Needle Nose Pliers Gloves 7/16”, 1/2”, 9/16” Sockets 7/16” Socket Driver 3/8”, 7/16”, 1/2”, 9/16” Wrenches Safety Glasses PRE-INSTALLATION Tools Required Step Ladder Hammer vice grips Vice clamps (2) Saw 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 d
P1 Tools Needed: Approved Winding Bars 3/8” Wrench Vice Clamp Recommended tools from page 5 Torsion Spring Removal For Standard Lift WARNING TORSION SPRING ASSEMBLY Failure to use approved winding bars can cause spring energy to be released suddenly, resulting in severe or fatal injury. WARNING COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.
Tools Needed: Recommended tools from page 5 loosen lock nut 1/4 turn counter gear/ cover A TorqueMaster® spring system can be identified by the end brackets. For single spring applications, the right hand end bracket will always have a drive gear, counter gear, counter cover, and a winding bolt head. The left hand end bracket will have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged.
TorqueMaster® Spring Removal continued... Tools Needed: Recommended tools from page 5 should be free to rotate in either direction. If the counterbalance cable is still taut and the TorqueMaster® Spring Tube is difficult to rotate, that is an indication that spring tension still exists on the left hand spring. Repeat Steps 1 and 2 for releasing spring tension on the left hand side. Step 4: Using a flat tip screwdriver, pry the counter gear and counter cover from the right hand end bracket (Fig.
Tools Needed: Recommended tools from page 5 Extension Spring Removal Step 1: Raise the door to the fully open position and place vice clamps to the back legs of both vertical tracks, below the bottom rollers to prevent the door from falling. By opening the door you release most of the spring tension. Carefully unfasten the S-hook from the horizontal angle. Remove cable, sheave and extension spring. Repeat for the other side. If safety cables are running through the extension springs, remove them also.
P5 Tools Needed: Recommended tools from page 5 Preparing the Opening WARNING Failure to securely attach a suitable mounting pad to structurally sound framing could cause springs to violently pull mounting pad from wall, resulting in severe or fatal injury. If you just removed your existing door or you are installing a new door, complete all steps in preparing the opening.
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). Stainless steel lag screws are NOT necessary when installing products on un-treated lumber.
2 Tools Needed: None Attaching Fully Adjustable Flagangles to Vertical Track Fully Adjustable flagangle NOTE: If quick install flagangles was installed in Step 1, skip this step and continue with Step 3. If not, complete this step. Hand tighten the flagangle to the vertical track using (2) 1/4” - 20 x 9/16” large head ribbed track bolts and (2) 1/4” - 20 flange hex nuts. Repeat for other side.
Tools Needed: None Installing Q.I. Jamb Brackets Measure the length of the vertical tracks. Using the jamb bracket schedule, 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.
6 Tools Needed: Level Bottom Section Before installing the bottom section, the weather seal (may not be included) 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.
8 Tools Needed: Power Drill 7/16” Socket Driver Stacking Sections NOTE: For door section identification see page 4. ION ECT S CK LO NOTE: Make sure hinges are flipped down, when stacking another section on top. IMPORTANT: Push & hold the hinge leaf against section while securing with 1/4”-14 x 5/8” self tapping screws. End Hinges have (2) screws and Intermediate hinges have (3) screws. NOTE: Install lock at this time (sold separately) see instructions in OPTIONAL SIDELOCK INSTALLATION on page 40.
10 Tools Needed: Power Drill 7/16” Socket Driver (2) Saw Horses operator bracket (installed in the step 12) U-Bar NOTE: If you have a model 9400/9600 Series door with windows in the top section or 9100 Sonoma (8’ high), skip this step and complete Step 11. NOTE: Model 9100 Series door over 13’ wide require a 3” U-Bar (supplied). Place the 3” u-bar over the top rib. Fasten each end of the u-bar to the endcap with (2) 1/4”- 20 x 11/16” self drilling screws.
Tools Needed: Power Drill 7/16” Socket Driver Vice Clamps Phillips Head Screwdriver Operator Bracket NOTE: Operator bracket must be mounted and secured prior to installing top section. IMPORTANT: WHEN CONNECTING A TROLLEY TYPE GARAGE DOOR OPENER TO THIS DOOR, A Wayne-Dalton OPENER/TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY U-BARS PROVIDED WITH THE DOOR.
13 Tools Needed: Hammer door width +3-3/8” to 3-1/2” Top Section Place the top section in the opening. 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 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.
9/16” Socket Ratchet Wrench 9/16” Wrench Level NOTE: If you have fully adjustable flagangle, skip this step and complete Step 15. To install horizontal track, place the curved end over the top roller. Align key slot of the horizontal track with the quick install tab of the flagangle. Push curved portion of horizontal track down to lock in place.
15 Tools Needed: 7/16” Socket 9/16” Socket Ratchet Wrench 9/16” Wrench Level Flat Tip Screwdriver Attaching Horizontal Track to Adjustable Flagangle flagangle NOTE: If quick install flagangles were installed in Step 14, skip this step and continue with Step 16. If not, complete this step. To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track with the vertical track.
16 Tools Needed: 7/16” Wrench HORIZONTAL track Adjusting Top Brackets With horizontal tracks installed, you can now adjust the top brackets. Vertically align the top section of the door with the lower sections. Once aligned, position the top bracket slide, out against the horizontal track. top SECTION TOP BRACKET SLIDE INSTALLATION Maintaining the slide’s position, tighten the (2) 1/4” - 20 flange hex nuts to secure the top roller slide to the top bracket base.
17 Tools Needed: None TorqueMaster® Spring Tube TorqueMaster® springs come lubricated and pre-assembled inside the 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 18 Tools Needed: None Center Bracket Bushing CENTER BRACKET ASSEMBLY NOTE: If you are installing the idrive® opener on your garage door, skip this step and continue with Step 19.
Tools Needed: idrive® Installation NOTE: See idrive® main installation instructions and owner’s manual for idrive® parts. IMPORTANT: Right and left hand is always determined from inside the garage looking out. With the TorqueMaster® spring tube on the floor (inside garage) in front of the door with the labeled end to the left. Look into the opener’s left side to ensure the left hand bearing and the internal (black) sleeve are aligned with the TorqueMaster® spring tube profile.
20 Tools Needed: None Drum Wraps IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE 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 tube assembly with the tabs facing left. Continue sliding the left hand drum wrap towards the center of the TorqueMaster® spring tube assembly.
21 Tools Needed: Tape Measure TorqueMaster® Spring Tube Assembly Cable Drums Shake the TorqueMaster® spring tube assembly gently to extend the winding shafts out about 5" on each side. For single spring applications, there will be no left hand spring in the TorqueMaster® spring tube assembly. Winding Shaft Lift the TorqueMaster® spring tube assembly and rest it on the top of the flagangles. 5” NOTE: Cable drums are marked right and left hand.
22 Tools Needed: Power Drill 7/16” Socket Driver 5/16” Wrench End Brackets Splines Disconnect Cable Guide Hole Winding Shaft IMPORTANT: Warning Tags must be securely attached to both End Brackets. Groove End brackets are right and left hand. You can identify the right hand end bracket by the disconnect cable guide hole in the top of the bracket. Warning Tag Use this these labe Illus trat l.
23 Tools Needed: Power Drill 1/8” Drill Bit 7/16” Socket Driver Securing Center Bracket Assembly NOTE: If you are installing the idrive® opener on your garage door, skip this step and continue with Step 24. CENTER BRACKET bushing ASSEMBLY NOTE: If you are not installing the idrive® opener on your garage door, you must install the center bracket bushing assembly. Follow these instructions for non-idrive® operated garage doors.
24 Tools Needed: Power Drill 1/8” Drill Bit 7/16” Socket Driver Positioning Support Bracket NOTE: See idrive® main installation instructions and owner’s manual for idrive® parts. 45° ANGLE Antenna Wire Mounting Surface NOTE: idrive® must be installed on a solid mounting surface. Locate the mounting surface. The mounting surface is a vertical board running directly above the center of the door. Remove (2) 1/4”-20 flange nuts from bottom of opener.
25 Tools Needed: Pliers Attaching Disconnect Cables S-Hook NOTE: See idrive main installation instructions and owner’s manual for idrive® parts. ® Disconnect Cable Attach the loose disconnect cable (located in opener hardware bag) to the opener with the “S” hook. Close both ends of the “S” hook (with pliers) to lock assembly together. Use this these label.
27 Tools Needed: Phillips head screwdriver Wire cutters Attaching Disconnect Handle NOTE: See idrive® main installation instructions and owner’s manual for idrive® parts. Note: Bring motor to the down position by pulling the disconnect cable, insure opener disconnect teeth are engaged before installing disconnect handle. Start the #6-20 x 1/2" screw into the disconnect handle. Thread the disconnect cable through the top of the disconnect handle bracket and then the disconnect handle.
28 Tools Needed: Vice Clamps Securing Door for Spring Winding Place vice clamps onto both vertical tracks just above the third roller. This is to prevent the garage door from raising while winding counterbalance springs. WARNING Failure to place vice clamps onto vertical Track can allow door to raise and cause severe or fatal injury. place vice clamps above 3rd Roller I MPORTANT: DO NOT USE IMPACT GUN TO WIND SPRING(S).
30 Tools Needed: None Drum Wrap Installation To install drum wraps, position the left hand drum wrap over the left hand drum, align with counterbalance cable; slide groove in drum wrap towards the left until tabs snap over drum in between drum and ratchet gear. Repeat for right hand side. drum wrap (left hand) drum (left hand) IMPORTANT: Right and Left hand are always determined from inside the Garage looking out.
Winding Springs Continued... Tools Needed: IMPORTANT: pawl knob must be in upper position to add/ remove required number of spring turns. End Bracket After 2-3 turns, remove the ratchet wrench and adjust the cable on the left side (step 29). Ensure the cables are in the first groove and the cable drums, as shown in Step 29. NOTE: Single spring application require no spring winding on the left hand side, but meed cable tension adjustments.
31 Tools Needed: Ratchet Wrench 1/2” Socket 1/2” Wrench (2) Vice Clamps Tape Measure Level Hammer Rear Support WARNING DOOR IN THE UP POSITION Keep horizontal track parallel and within 3/4” maximum of door edge, otherwise door could fall, resulting in severe injury or death. Raise the door until the top section and half of the next section are in a horizontal position. Do not raise door any further since rear of horizontal track is not yet supported.
Rear Support Continued... Sound Framing Members Adjust, if door lifts by itself (hard to pull down) or if door is difficult to lift (easy to pull down). Anytime spring adjustments are made, ratchet pawl knob must be in the upper position to add/remove required number of spring turns (refer to step 29). To adjust springs, only add or remove a maximum of 3/10 of a turn (three teeth of ratchet wheel) at a time. Both sides need to be adjusted equally on double spring doors.
❉ Tools Needed: 5/8” Socket Ratchet Wrench 3” Extension Vice Clamps (Pair) 3” Extension ENGAGEMENT SIDE VIEW TorqueMaster® Plus Reset Instructions WARNING READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO RESET THE TORQUEMASTER® SYSTEM. IF IN QUESTION ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A QUALIFIED DOOR AGENCY RESET THE SYSTEM. Ratchet Pawl WARNING ALWAYS KEEP MOVING DOOR IN SIGHT AND KEEP PEOPLE AND OBJECTS AWAY UNTIL IT IS COMPLETELY CLOSED.
TorqueMaster® Plus Reset Instructions Continued... Tools Needed: If the system is activated, follow these steps to reset the system: 3. Clamp vice grips on both vertical tracks just below the bottom section. 4. Flip the pawl knob on both end brackets to the upper position (see illustration). place vice clamps BELOW BOTTOM SECTION on both vertical track 5. With assistance, raise the door slightly to reset the system. 6.
TorqueMaster® Plus Reset Instructions Continued... Tools Needed: NOTE: Single spring applications require no spring winding on left hand side. place vice clamps above 3rd Roller on both vertical track Clamp a pair of vice clamps on the vertical tracks just above the third roller on one side and just below the third roller on the other side. This will prevent the door from raising or lowering while adjusting the spring(s).
❉ Tools Needed: Power Drill 7/16” Socket Driver 1/8” Side Lock Install the side lock on the second section of the door. Secure the lock to the section with (4) 1/4”- 20 x 11/16” self drilling screws. Square the lock assembly with the door section and align with the square hole in the vertical track. The side lock should be spaced approximately 1/8” from the section edge. IMPORTANT: side locks must be removed or made inoperative in the unlocked position if an operator is installed on the door.
❉ Tools Needed: 7/16” Drill Bit Power Drill 7/16" Wrench Step Plate STEP PLATE OUTSIDE Make one mark 1” (25 mm) up from the center of bottom edge of the bottom section and another mark 2-3/16” (56 mm) up from the first mark. Note: Top of step plate can be no higher then 6” from the bottom of the door. Drill a 7/16” (11 mm) hole through the section at each mark and insert the outside step plate.Loosely fasten step plate slide to base with (1) 1/4” - 20 x 5/8” carriage bolt and nut.
Tools Needed: Power Drill 1/8” Drill Bit Pull Rope WARNING DO NOT INSTALL PULL ROPES ON DOORS WITH ELECTRIC OPERATORS. CHILDREN MAY BECOME ENTANGLED IN THE ROPE CAUSING SEVERE OR FATAL INJURY. Measure and mark the jamb approximately 48” to 50” (1220 to 1270 mm) from floor on the right or left side of jamb. Drill 1/8” pilot hole for No. 6 screw eye. Tie the pull rope to the No. 6 screw eye and to the bottom bracket as shown. NO.
❉ Trolley Installation for Standard Lift Measure the curved ends of the horizontal track to determine if you have a 12” or 15” radius horizontal track, as shown in FIG. 2.1. Determine center line of door. Mark vertical line at this point, on the header wall. Raise the door slightly until the top section reaches the highest point of travel (high arc). Using a level, mark this high arc point of travel on the header wall, intersecting the vertical center line, as shown in FIG. 2.2 through 2.3.
Determine center line of door. Mark vertical line at this point, on the header wall. Raise the door slightly until the top section reaches the highest point of travel (high arc). Using a level, mark this high arc point of travel on the header wall, intersecting the vertical center line, as shown in FIG. 3.1 through 3.2. Hold the wall bracket’s bottom edge to the appropriate 1/2” - 1” (room permitting) above of the high arc line and centered on the vertical line, as shown in FIG. 3.2.
❉ Tools Needed: Trolley Operator WARNING 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 PASS THIS TEST REQUIRES IMMEDIATE ADJUSTMENTS OR REPAIRS. FAILURE TO MAKE ADJUSTMENTS, IF NECESSARY, CAN RESULT IN SEVERE OR FATAL INJURY.
Cleaning While factory-applied finishes on steel 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. Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, an annual washing of the door is recommended.
Painting Continued.... After surface has been properly prepared, it must be allowed to dry thoroughly, then coated immediately with a premium quality latex house paint. Follow paint label directions explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate is exposed and not properly primed, painting with latex paint may cause accelerated rusting of the steel in the exposed area. NOTES: 1.
Lifetime Limited Warranty Models 9100, 9400, 9600 Subject to the terms and conditions contained in this Lifetime Limited Warranty, Wayne-Dalton (“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: (i) 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
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; 2,477,445; 2,495,175; 2,507,590; 2,530,701; 2,530,74; 2, 2,532,824. Other US and Foreign Patents pending.