Wayne Dalton 9100, 9405, 9600 garage door Installation instructions

Below you will find brief information for garage door 9100, garage door 9405, garage door 9600. This manual will guide you through the installation of your new Wayne Dalton garage door. These instructions are designed to provide you with the information needed for a safe and proper installation. Please read these instructions carefully before attempting installation. If in question about any of the procedures, do not perform the work. Instead, have a trained door systems technician do the installation or repairs.

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9100 / 9405 / 9600

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Pre-Installation 2

Important Safety Instructions

Tools Required

Package Contents

Door Section Identification

Removing an Existing Door

Preparing the Opening

Parts Breakdown 5

Installation 6

Optional Installation 16

Door Arm Hookup

Trolley Arm Configuration

Inside Lock

Pull Down Rope

Step Plate

Maintenance 18

Cleaning Your Garage Door

Painting Your Garage Door

Maintaining The Finish On Your Garage Door

Operation And Maintenance

Warranty 19

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

Please Do Not Return This Product To The

Store. Please call 1-866-569-3799 (Press

Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.

IMPORTANT NOTICES!

Wayne Dalton highly recommends that you read and fully understand the Installation Instructions and Owner’s Manual before you attempt this installation.

To avoid possible injury, read the enclosed instructions carefully before installing and operating the garage door. Pay close attention to all warnings and notes. After installation is complete, fasten this manual near garage door for easy reference.

DEFINITION OF DOOR HEIGHTS:

1. Door Heights less than or equal to 8’0” (< = 8’0”) are considered

Standard Lift Applications.

2. Door Heights greater than 8’0” (> 8’0”) are considered Light

Commercial Applications.

The complete Installation Instructions and Owner’s Manual are available at no charge from:

Wayne-Dalton, a Division Of Overhead Door Corporation,

P.O. Box 67, Mt. Hope, OH., 44660, Or Online At

www.Wayne-Dalton.com.

Part Number 348711 REV3_05/08/2015

Pre-Installation

Important Safety Instructions

DEFINITION OF KEY WORDS USED IN THIS MANUAL:

INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH; IF NOT

AVOIDED, COULD RESULT IN SEVERE OR FATAL INJURY.

CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT FROM FAILURE TO

FOLLOW INSTRUCTIONS.

IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER DOOR OPERATION.

NOTE: Information assuring proper installation of the door.

READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING INSTALLATION. IF IN QUES-

TION ABOUT ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD, HAVE A

TRAINED DOOR SYSTEMS TECHNICIAN DO THE INSTALLATION OR REPAIRS.

1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

Wear protective gloves during installation to avoid possible cuts from sharp metal edges.

It is always recommended to wear eye protection when using tools, otherwise eye injury could result.

4. Avoid installing your new door on windy days. Door could fall during the installation causing severe or fatal injury.

5. Doors 12’-0” wide and over should be installed by two persons, to avoid possible injury.

6. Operate door only when it is properly adjusted and free from obstructions.

7. If a door becomes hard to operate, inoperative or is damaged, immediately have necessary adjustments and/ or repairs made by a trained door system technician using proper tools and instructions.

DO NOT stand or walk under a moving door, or permit anybody to stand or walk under an electrically operated door.

DO NOT place fingers or hands into open section joints when closing a door. Use lift handles/ gripping points when operating door manually.

10. DO NOT permit children to operate garage door or door controls. Severe or fatal injury could result should the child become entrapped between the door and the floor.

11. Due to constant extreme spring tension, do not attempt any adjustment, repair or alteration to any part of the door, especially to springs, spring brackets, bottom corner brackets, fasteners, counterbalance lift cables or supports. To avoid possible severe or fatal injury, have any such work performed by a trained door systems technician using proper tools and instructions.

12. On electrically operated doors, pull down ropes must be removed and locks must be removed or made inoperative in the open (unlocked) position.

13. Top section of door may need to be reinforced when attaching an electric opener.

Check door and/ or opener manufacturer’s instructions.

14. Visually inspect door and hardware monthly for worn and or broken parts. Check to ensure door operates freely.

15. Test electric opener’s safety features monthly, following opener manufacturer’s instructions.

16. NEVER hang tools, bicycles, hoses, clothing or anything else from horizontal tracks.

Track systems are not intended or designed to support extra weight.

17. This door may not meet the building code wind load requirements in your area. For your safety, you will need to check with your local building official for wind load code requirements and building permit information.

After installation is complete, fasten this manual near the garage door.

IMPORTANT: STAINLESS STEEL OR PT2000 COATED LAG SCREWS MUST BE USED WHEN

INSTALLING CENTER BEARING BRACKETS, END BRACKETS, JAMB BRACKETS, DRAWBAR

OPERATOR MOUNTING/ SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED

LUMBER (PRESERVATIVE-TREATED). STAINLESS STEEL OR PT2000 LAG SCREWS ARE NOT

NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.

NOTE: It is recommended that 5/16” lag screws are pilot drilled using a 3/16” drill bit, prior to fastening.

IMPORTANT: WHEN INSTALLING 5/16” LAG SCREWS USING AN ELECTRIC DRILL/ DRIVER,

THE DRILL/ DRIVERS CLUTCH MUST BE SET TO DELIVER NO MORE THAN 200 IN-LBS OF

TORQUE. FASTENER FAILURE COULD OCCUR AT HIGHER SETTINGS.

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING

LOOKING OUT.

Tools Required

Power drill

Drill bits: 1/8”, 3/16”, 9/32”,

7/16”, 1/2”

Ratchet wrench

Socket driver: 7/16”

Sockets: 7/16”, 1/2”, 9/16”,

5/8”

Phillips head screwdriver

Locking Pliers

(2) Vice clamps

Wrenches: 3/8”, 7/16”, 1/2”,

9/16”, 5/8”

1/4” Torx bit

Approved winding rods

Hammer

Tape measure

Step Ladder

Level

Pencil

Saw Horses

Leather gloves

Safety glasses

Package Contents

NOTE: Depending on the door model, some parts listed will not be supplied if not required.

Rear Back Hangs may not be included with your door.

Jamb brackets

(as required)

Pull down rope

(if included)

Vertical tracks RH/LH (as required)

Horizontal tracks RH/LH

Flag angles RH/LH (as required)

Weather seals & nails

(If included)

Drawbar operator bracket

Track rollers

(as required)

Strut (U-shaped)

(if included)

Strut (A-symmetrical)

(if included)

Top fixture bases (as required)

2

Torsion springs RH/LH Cable drums RH/LH

Head plates / End bearing bracket RH/LH (as required)

Center bracket bushing (as required)

Center coupler assembly

(as required)

1/4”-20 x 9/16”

Track bolts (as required)

Cotter pin

5/16” x 1-1/4” Clevis pin

Spring anchor bracket

/ Center bracket (as required)

Keys

(as required)

1/4”-20 x 11/16” Self drilling screws (as required)

3/8” - 16 x 1-1/2” Hex head bolts

(as required)

Warning label

Top section

Intermediate IV section

Intermediate III section

Intermediate II section

Warning labels

Intermediate I section

1/4”-20 x 5/8”

Carriage bolts (as required)

3/8”-16 x 3/4” Hex bolts

(as required)

(2) #12 x 1/2”

Phillips head screws

(2) 3/8”- 16 Hex nuts

(as required)

1/4”-14 x 5/8” Self tapping screws (as required)

1/4”- 20 Flanged hex nuts (as required)

Lock section

Bottom weather seal

Bottom corner bracket warning labels

Bottom section

Typical graduated end hinge stamping location

7/8”

#1 Graduated end hinge

Bottom corner bracket

Bottom weather seal

Section side view illustration

5/16” x 2” Hex head lag screws

(as required)

5/16” x 2” Tamper-resistant hex head lag screw (as required)

Door Section Identification

Graduated end and center hinges are always pre-attached at the top of each section (except top section) and the graduated end hinges are stamped for identification, #1, #2, #3, #4, #5 and #6. The stamp identifies the stacking sequence of the section. The sequence is always determined by #1 being the bottom section to #5 or #6 being the highest intermediate section. If the stamp on the graduated end hinge is illegible, refer to the section side view illustration. The section side view illustration shows the graduated end hinge profile of all sections, and can also be used to identify each section.

The

BOTTOM SECTION can be identified by #1 graduated end hinges, the factory attached bottom astragal, the factory attached bottom corner brackets and by the bottom corner bracket warning labels on each end stile.

The LOCK SECTION can be identified by #2 graduated end hinges.

The INTERMEDIATE SECTION I can be identified by #3 graduated end hinges. The intermediate I section will have a warning label attached to either the right or left hand end stile.

The

INTERMEDIATE SECTION II can be identified by #4 graduated end hinges.

The INTERMEDIATE SECTION III can be identified by #5 graduated end hinges.

The

INTERMEDIATE SECTION IV can be identified by #6 graduated end hinges.

The TOP SECTION can be identified with no pre-installed graduated end or center hinges.

Removing an Existing Door

IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE

ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.

3

A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE

SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR

SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS,

RELEASE THE SPRING TENSION.

For detailed information see supplemental instructions “Removing an Existing Door/ Preparing the Opening”. These instructions are not supplied with the door, but are available at no charge from Wayne Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope,

OH., 44660, or at

www.Wayne-Dalton.com.

Preparing the Opening

IMPORTANT: IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A

NEW DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING.

To ensure secure mounting of track brackets, side and center brackets, or steel angles to new or retro-fit construction, it is recommended to follow the procedures outlined in DASMA technical data sheets #156, #161 and #164 at www.dasma.com.

The inside perimeter of your garage door opening should be framed with wood jamb and header material. The jambs and header must be securely fastened to sound framing members. It is recommended that 2” x 6” lumber be used. The jambs must be plumb and the header level. The jambs should extend a minimum of 12” (305 mm) above the top of the opening for Torsion counterbalance systems. For low headroom applications, the jambs

2”

Graduated end hinge

1-7/8”

Graduated end hinge

1-5/8”

Graduated end hinge

1-3/8”

#3 Graduated end hinge

1-1/8”

#2 Graduated end hinge

should extend to the ceiling height. Minimum side clearance required, from the opening to the wall, is 3-1/2” (89 mm).

IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD

FOUND NOT TO BE SOUND, MUST BE REPLACED.

For Torsion counterbalance systems, a suitable mounting surface (2” x 6”) must be firmly attached to the wall, above the header at the center of the opening.

NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting the lumber. Do not attach the mounting surface with nails.

WEATHERSTRIPS (MAY NOT BE INCLUDED):

Depending on the size of your door, you may have to cut or trim the weatherstrips (if necessary) to properly fit into the header and jambs.

NOTE: If nailing product at 40°F or below, pre-drilling is required.

NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.

For Quick Install track: For the header, align the weatherstrip with the inside edge of the header and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and flush with the inside edge of the jamb. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.

For Fully Adjustable track: For the header, align the weatherstrip 1/8” to 1/4” inside the header edge, and temporarily secure it to the header with equally spaced nails. Starting at either side of the jamb, fit the weatherstrip up tight against the temporarily attached weatherstrip in the header and 1/8” to 1/4” inside the jamb edge. Temporarily secure the weatherstrip with equally spaced nails. Repeat for other side. This will keep the bottom section from falling out of the opening during installation. Equally space nails approximately 12” to 18” apart.

Headroom requirement: Headroom is defined as the space needed above the top of the door for tracks, springs, etc. to allow the door to open properly. If the door is to be motor operated, 2-1/2” (64 mm) of additional headroom is required.

NOTE: 6” low headroom conversion kit is available for 12” radius only. Contact your local

Wayne Dalton dealer.

Backroom requirement: Backroom is defined as the distance needed from the opening back into the garage to allow the door to open fully.

*NOTE: For door heights from 10’1” to 14’0”, refer to your operator manufacture installation instructions for appropriate depth into room.

BACKROOM REQUIREMENTS

Door Height Track Manual Lift Motor Operated

6’0” to 7’0”

7’1” to 8’0”

8’1” to 9’0”

9’1” to 10’0”

10’1” to 12’0”

12’1” to 14’0”

12”, 14” Radius

102” (2591 mm)

114” (2896 mm)

126” (3200 mm)

138” (3505 mm)

162” (4115 mm)

186” (4724 mm)

125” (3175 mm)

137” (3480 mm)

168” (4267 mm)

See *NOTE

HEADROOM REQUIREMENTS

Track Type

12” Radius

14” Radius

Space Needed

13-1/2” (343 mm)

14-1/2” (368 mm)

Suitable mounting surface

2”x 6” lumber minimum

Header board 2”x 6” lumber preferred

Headroom

Min. Side room

Clearance is 3 1/2”

Min. Side room

Clearance is 3 1/2”

Backroom

Nail

Level header

Weatherstrips

Finished

Door

Height

Plumb jambs

Finished

Door width

Jambs

Weatherstrips

Jamb

Quick Install track

Jamb

Other track systems

1/8” to 1/4”

Weatherstrips

4 PARTS BREAKDOWN

NOTE: The illustrations shown on this page are general representations of the door parts. Each specific door models may have unique variations.

J5.

J3.

J6.

J5.

J9.

J4.

J5.

J9.

J8.

J1.

J6.

J10.

J5.

J9.

J8.

J1.

J7.

A1.

E1.

J9.

J4.

F3.

F1.

J3.

J2.

F2.

C1.

A1.

I3.

G1.

J3.

I3.

F2.

F3.

C1.

F1.

E2.

B1.

K3.

G2.

I1.

K2.

K1.

H1.

NOTE: For Item (K2), The Rear Center Back Hang

Assemblies are to used for all doors over 11’0” door height and over 14’0” door width. One Rear Center

Back Hang Assembly, per side.

J2.

K2.

E3.

I2.

NOTE: For Item (K3), The Rear Center Back Hang

Assemblies are to used for all doors over 16’0” door height. Two Rear Center Back Hang Assemblies, per side.

E4.

D2.

I1.

K1.

NOTE: Depending on your door weight and door height, you may have bigger springs. The illustration shown below is a typical example.

D1.

C1.

C2.

J1.

B1.

J2.

A. FLAG ANGLES (AS REQUIRED):

A1. Flag Angles

B. JAMB BRACKETS (AS REQUIRED):

B1. Jamb Brackets

C. TRACK ROLLERS:

C1. Short Stem Track Rollers

C2. Long Stem Track Rollers

D. GRADUATED END HINGES:

D1. Single Graduated End Hinges (S.E.H.), Anti-Pinch

D2. Double Graduated End Hinges (D.E.H.), Anti-Pinch

E. STACKED SECTIONS:

E1. Top Section

E2. Intermediate(s) Section

E3. Lock Section

E4. Bottom Section

F. TOP FIXTURE (AS REQUIRED):

F1. Top Fixture Bases - (L-Shaped)

F2. Top Fixture Slides - (L-Shaped)

F3. Top Fixture Assemblies

G. STRUT(S) (AS REQUIRED):

G1. Strut (U-shaped)

G2. Strut (A-symmetrical)

H. DRAWBAR OPERATOR BRACKET (FOR TROLLEY OPERATED DOORS):

H1. Drawbar Operator Bracket

I. TRACKS (AS REQUIRED):

I1. Left Hand and Right Hand Horizontal Track Assembly

I2. Left Hand and Right Hand Vertical Tracks

I3. Left Hand and Right Hand Angle Mount Vertical Track Assembly

J. TORSION SPRING ASSEMBLY (AS REQUIRED):

J1. Left Hand and Right Hand Torsion Springs (As Required)

J2. Counterbalance Lift Cables

J3. Left Hand and Right Hand Head Plates / End Bearing Brackets (As Required)

J4. Left Hand and Right Hand Cable Drums

J5. Center Bracket (As Required)

J6. Spring Anchor Bushing / Center Bracket Bushing (As Required)

J7. Torsion Shaft / Torsion Keyed Shaft (As Required)

J8. Torsion Keyed Shafts (As Required)

J9. Keys (As Required)

J10. Center Coupler Assembly (As Required)

K. REAR BACK HANGS (AS REQUIRED):

K1. Left Hand and Right Hand Rear Back Hang Assemblies

K2. Left Hand and Right Hand Center Back Hang Assemblies

5

1st hole set 2nd hole set 3rd hole set

Top of track

INSTALLATION

Before installing your door, be certain that you have read and followed all of the instructions covered in the pre-installation section of this manual. Failure to do so may result in an improperly installed door.

NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.

Vertical Tracks

Tools Required: Power drill, 5/16” Drill bit, Hacksaw, Tape measure, Safety glasses, Leather gloves

NOTE: If you have a wall angle track assembly, skip this step.

NOTE: Refer to Door Section Identification / Parts Breakdown, to determine if you have vertical tracks.

Vertical tracks may or may not have to be cut to the proper length, prior to installing.

IMPORTANT: VERTICAL TRACKS ARE NOT REQUIRED TO BE CUT DOWN IF YOU HAVE DOOR

HEIGHTS 7’-0” OR 8’-0”.

Determine the radius of your horizontal track.

12”

Stamped radius

Horizontal track

Refer to the vertical track cutting chart to determine the length needed to be cut off at the top of the vertical tracks. Using this measurement, measure and cut the vertical track off at the top, as shown. Remove any burrs from the cut edge of vertical track.

Horizontal Track Radius

Vertical Track Cutting Chart

Vertical Track Cut Length

10” Or 12” Radius

14” Radius

Door Height Minus 10”

Door Height Minus 8”

Measure and cut

Vertical track

Top of track

Now, two holes must be drilled into the top of the cut vertical track. Using the illustration shown below, mark and drill the hole locations using a 5/16” drill bit. Once the holes have been drilled, remove any burrs from the drilled holes. Repeat the same process for the other vertical track.

5/8”

1/2”

Measure and drill

5/16” Holes 5/8”

Vertical track

Jamb Brackets

Tools Required: Tape measure, Safety glasses, Leather gloves

NOTE: If you have a wall angle track assembly, skip this step. Refer to Package Contents /

Parts Breakdown, to determine if you have flag angles.

NOTE: The bottom jamb bracket is always the shortest bracket or the lowest number marked on the jamb bracket. The center jamb bracket is the next tallest or the next higher number marked on the jamb bracket. If three jamb brackets per side are included with your door, you will have received a top jamb bracket, which is the tallest or the highest number marked on the jamb bracket.

To attach the bottom jamb bracket, locate lower slot pattern of the 1st hole set on the vertical track. Align the slot in the jamb bracket with the lower slot pattern. Loosely, secure jamb bracket using (1) 1/4” - 20 x 5/8” carriage bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.

Place the center jamb bracket over the slot pattern that is centered between the bottom jamb bracket and flag angle of the 2nd hole set. Loosely, secure jamb bracket using (1) 1/4” - 20 x

5/8” carriage bolt and (1) 1/4” - 20 flange hex nut. Repeat for other side.

If a top jamb bracket was included, loosely secure it to vertical track using the slot pattern in the 3rd hole set and (1) 1/4” - 20 x 5/8” carriage bolt and (1) 1/4” - 20 flange hex nut.

Repeat the same process for the other vertical track.

Slot pattern

1/4”- 20

Flange hex nut

Jamb bracket

Vertical track

1/4”- 20 x 5/8”

Carriage bolt

Jamb bracket in place

Flag Angles

Tools Required: Tape measure, Safety glasses, Leather gloves

NOTE: If you have a wall angle track assembly, skip this step. Refer to Package Contents /

Parts Breakdown, to determine if you have flag angles.

NOTE: Flag angles are right and left handed.

Hand tighten the left hand flag angle to the left hand vertical track using (2) 1/4” - 20 x 5/8” carriage bolts and (2) 1/4” - 20 flange hex nuts. Repeat for other side. Flange nuts will be secured after flag angle spacing is completed in step, Top Section.

Flag angle

(2) 1/4”-20

Flange hex nuts

Vertical track

(2) 1/4”- 20 x 5/8”

Carriage bolts

Counterbalance Cables and Track Rollers

Tools Required: Tape measure, Safety glasses, Leather gloves

NOTE: The bottom section can be identified by the smallest graduated edge hinge of the factory installed graduated edge hinges, see Door Section Identification.

WARNING

FAILURE TO ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN

COULD RESULT IN COUNTERBALANCE LIFT CABLE COMING OFF THE PIN,

ALLOWING THE DOOR TO FALL, POSSIBLY RESULTING IN SEVERE OR

FATAL INJURY.

Uncoil the counterbalance lift cables. Starting on the left hand side, place the left hand cable loop on the left hand milford pin of the bottom corner bracket. Insert a short stem track roller into the bottom corner bracket. Insert a short stem track roller into the #1 graduated end hinge at the top of the bottom section. Repeat for other side.

NOTE: Larger doors will use long stem track rollers with double graduated end hinges.

NOTE: Check to ensure cable loops fits tightly over the milford pins.

NOTE: Verify bottom weather seal is aligned with bottom section. If there is more than 1/2” excess weather seal on either side, trim weather seal even with bottom section.

6

in the wall angle, maintain 3/8” to 5/8” spacing as shown between the bottom section and vertical track. Hang counterbalance lift cable over angle mount. Repeat same process for other side.

#1 Single graduated end hinge (Hinge tube)

Short stem track roller

Counterbalance lift cable

Long stem track roller

Double graduated end hinge (Hinge tube)

Bottom section

Bottom corner bracket warning label

Cable loop

Milford pin

Bottom weather seal

Bottom corner bracket

Short stem track roller

Bottom Section

Tools Required: Tape measure, Level, Wooden shims (if necessary), Safety glasses, Leather gloves

Center the bottom section in the door opening. Level the section using wooden shims (if necessary) under the bottom section. When the bottom section is leveled, temporarily hold it in place by driving a nail into the jamb and bending it over the edge of the bottom section on both sides.

Weather seal (If applicable)

Level

Bottom section

Wooden shims (If necessary)

Vertical Tracks

Tools Required: Power drill, 3/16” Drill bit, 7/16” Socket driver, Tape measure,

Level, Step ladder, Safety glasses, Leather gloves

NOTE: Depending on your door, you may have Flag Angles or you may have Angle Mount

Vertical Track Assemblies. Refer to Package Contents / Parts Breakdown, to determine which

Flag Angles / Vertical Track Assemblies you have.

IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION

OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION

ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO

DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.

IMPORTANT: THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE.

IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ON THE

SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.

Starting on the left hand side of the bottom section, remove the nail. Position the left hand vertical track assembly over the track rollers of the bottom section. Make sure the counterbalance lift cable is located between the track rollers and the door jamb. Drill 3/16” pilot holes into the door jamb for the lag screws.

FOR FLAG ANGLES: Loosely fasten jamb brackets and flag angle to the jamb using 5/16” x

2” lag screws. Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing, between the bottom section and vertical track. Hang counterbalance lift cable over flag angle. Repeat same process for other side.

FOR ANGLE MOUNT VERTICAL TRACK ASSEMBLY: Loosely fasten the slots in the wall angle to the jamb using 5/16” x 2” lag screws. Tighten lag screws, securing the bottom slot

7

Wallangle track assembly

Flag angle

5/16” x 2”

Lag screws

Jamb bracket

Flag angle lag screw locations

Bottom section

2” Vertical track spacing (3/8” to 5/8”)

Bottom section

Track rollers

Vertical track assembly

Floor

Track roller

Stacking Sections

Tools Required: Power drill, 7/16” Socket driver, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

NOTE: The sections can be identified by the graduation of the factory installed graduated end hinges. The smallest graduated end hinge on section should be stacked on top of the bottom section, with each graduated end hinge increasing as the sections are stacked, see Door

Section Identification / Parts Breakdown.

NOTE: Make sure graduated end and center hinges are flipped down, when stacking another section on top.

NOTE: Larger doors will use long stem track rollers with double graduated end hinges.

Place track rollers into graduated end hinges of remaining sections.

With assistance, lift second section and guide the track rollers into the vertical tracks. Lower section until it is seated against bottom section. Flip hinges up. Fasten center hinge(s) first; then end hinges last using 1/4” - 14 x 5/8” self tapping screws.

NOTE: To prevent center hinge leaf(s) from rotating, first secure the top middle hole of the center hinge leaf with one 1/4” - 14 x 5/8” self-tapping screw then secure the other two holes.

NOTE: Larger doors with double graduated end hinges, fasten both hinges to connect the sections using 1/4” - 14 x 5/8” self-tapping screws.

Repeat same process for other sections, except top section.

IMPORTANT: PUSH & HOLD THE HINGE LEAFS SECURELY AGAINST THE SECTIONS WHILE

SECURING WITH 1/4” - 14 X 5/8” SELF TAPPING SCREWS. THERE SHOULD BE NO GAP

BETWEEN THE HINGE LEAFS AND THE SECTIONS.

NOTE: Install lock at this time (sold separately). See optional installation step, Side Lock.

Place the strut (U-shaped) over the top rib of the top door section. Fasten each end of the strut to the end cap with (2) 1/4” - 20 x 11/16” self drilling screws. Fasten center of the strut as shown to the rib using (2) 1/4” - 14 x 5/8” self tapping screws, one 6” to the left and one

6” to the right of the center line of the top door section.

(2) 1/4”-20 x 11/16”

Self drilling screws

End cap

(2) 1/4”-14 x 5/8”

Self tapping screws

Strut

(attached to top rib)

(2) 1/4”-20 x 11/16”

Self drilling screws

Lock section

(4) 1/4”- 14 x 5/8”

Self-tapping screws

Top fixture base

(2) 1/4”- 20

Flange hex nuts

Endcap hole pattern

IF YOU HAVE TOP FIXTURE ASSEMBLIES: Starting on the left hand side of the top section, place the top of the top fixture base flush with the top edge of section and even with the edge of the endcap. Fasten the top fixture assembly to the top section using (4) 1/4” - 20 x

7/8” self-drilling screws, one in each corner of the top fixture base. Next, loosen the 5/16” -

18 hex nut on the 5/16” - 18 x 5/8” carriage bolt.

Repeat the same process for the right hand side. The top fixtures will be tightened and adjusted later, in step, Adjusting Top Fixture.

Top section

Strut

(2) 1/4”-14 x 5/8”

Self-tapping screws

Top fixture slide

Short stem track roller

5/16” - 18 Hex nut and

5/16” - 18 x 5/8” Carriage bolt

(1)Top fixture assembly

Top fixture base

Endcap

(2) 1/4”-14 x 5/8” Self-tapping screws

Strut (U-shaped)

Tools Required: Power drill, 7/16” Socket driver, Step ladder, Tape measure,

Safety glasses, Leather gloves

NOTE: If a strut (U-shaped) is supplied, complete this step.

6” 6”

Center line of top section

Left double graduated end hinge with long stem track roller

Vertical tracks

Right double graduated end hinge with long stem track roller

1/4”-14 x 5/8” Self tapping screw locations

Secure top middle hole first

Left graduated end hinge with short stem track roller

Center hinge(s)

Right graduated end hinge with short stem track roller

Top Fixtures

Tools Required: Power drill, 7/16” Socket driver, Step ladder, Safety glasses,

Leather gloves

NOTE: Depending on your door, you may have Top Fixture Bases and Top Fixture Slides or you may have Top Fixture Assemblies. Refer to Package Contents / Parts Breakdown, to determine which Top Fixtures you have.

IF YOU HAVE TOP FIXTURE BASES AND TOP FIXTURE SLIDES: To install the top fixtures, align the top holes in the top fixture base with the second set of holes in the end cap of the top section. Fasten to section using (4) 1/4” - 14 x 5/8” self tapping screws. Secure the top fixture slide to the fixture base loosely using (2) 1/4” - 20 x 5/8” carriage bolts and (2) 1/4” -

20 flange hex nuts. The top fixture slide will be tightened and adjusted later, in step, Adjusting

Top Fixture. Insert track roller into top fixture slide. Repeat for other side.

Top fixture slide

(2) 1/4”- 20 x 5/8”

Carriage bolts

2nd Set

Short stem track roller

Top section

End cap

2nd Set

Strut (A-symmetrical)

Tools Required: Power drill, 7/16” Socket driver, Step ladder, Tape measure,

Safety glasses, Leather gloves

NOTE: If an a-symmetrical strut is supplied, complete this step.

Place the a-symmetrical strut over the top rib of the top door section. Fasten each end of the a-symmetrical strut to the end cap with (2) 1/4” - 20 x 11/16” self drilling screws. Fasten center of the a-symmetrical strut as shown to the rib using (2) 1/4” - 14 x 5/8” self tapping screws, one 6” to the left and one 6” to the right of the center line of the top door section.

Fasten both wall and the long leg of the a-symmetrical strut, as shown using (2) 1/4” - 14 x

5/8” self tapping screws every 30 - 36 inches. (Approximately 18 self tapping screws per 18’ a-symmetrical strut)

IMPORTANT: WHEN SECURING THE A-SYMMETRICAL STRUT TO THE TOP SECTION, IT

IS RECOMMENDED NOT TO INSTALL ANY FASTENERS INTO THE SHORT LEG OF THE A-

SYMMETRICAL STRUT.

(2) 1/4”-20 x 11/16”

Self drilling screws

(2) 1/4”-14 x 5/8”

Self tapping screws

(2) 1/4”-14 x 5/8”

Self tapping screws

(2) 1/4”-20 x 11/16”

Self drilling screws

Strut (A-symmetrical)

(attached to top rib)

End cap

30” To 36”

6” 6”

Center line of top section

Long leg

Strut (A-symmetrical) side view

Short leg

Drawbar Operator Bracket

Tools Required: Power drill, 7/16” Socket driver, Phillips head screwdriver, Vice clamps, Step ladder, Tape measure, Safety glasses, Leather gloves

NOTE: If you’re installing a drawbar operator, the drawbar operator bracket must be mounted and secured prior to installing top section.

IMPORTANT: WHEN CONNECTING A DRAWBAR OPERATOR TYPE GARAGE DOOR OPENER

TO THIS DOOR, A WAYNE DALTON OPERATOR/ DRAWBAR OPERATOR BRACKET MUST

BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY STRUT

PROVIDED WITH THE DOOR. THE INSTALLATION OF THE DRAWBAR OPERATOR MUST BE AC-

CORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED

PROPERLY.

Prior to installing the top section, locate the center of the top section and seat the drawbar operator bracket on top of the top section. For retro fit applications, the drawbar operator bracket must be aligned with an existing drawbar operator and positioned on top section so it bridges the transition point of the section thickness. Install (2) #12 x 1/2” phillips head screws on the back side of drawbar operator bracket. Clamp drawbar operator bracket to strut (if supplied) with vice clamps. Attach (6) 1/4” - 14 x 5/8” self-tapping screws to the drawbar operator bracket. Remove vice clamps.

NOTE: If a strut was installed, you can use two of the 1/4” - 20 x 11/16” self-drilling screws previously used to attach the strut instead of two 1/4” - 14 x 5/8” self-tapping screws when attaching drawbar operator bracket to strut.

NOTE: When attaching drawbar operator bracket to top section with strut, apply additional pressure to thread into the strut.

8

1/4”- 14 x 5/8”

Self-tapping screws

Backside of drawbar operator bracket

(2) #12 x 1/2”

Phillips head screws

Drawbar operator bracket

Top Section

Tools Required: Power drill, 7/16” Socket driver, 7/16” Wrench, Step ladder,

Tape measure, Safety glasses, Leather gloves

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 the hinge leaves, hold tight against section, and fasten center hinges first and end hinges last

(refer to step, Stacking Sections). Vertical track alignment is critical. Position flag angle or wall angle between 1-11/16” (43 mm) to 1-3/4” (44 mm) from the edge of the door; tighten the bottom lag screw. Flag angles or wall angles must be parallel to the door sections. Repeat for other side.

IMPORTANT: THE DIMENSION BETWEEN THE FLAG ANGLES OR WALL ANGLES MUST BE

DOOR WIDTH PLUS 3-3/8” (86MM) TO 3-1/2” (89 MM) FOR SMOOTH, SAFE DOOR OPERA-

TION.

FOR FLAG ANGLE: Complete the vertical track installation by securing the jamb bracket(s) and tightening the other lag screws. Push the vertical track against the track rollers so that the track rollers are touching the deepest part of the curved side of the track; tighten all the track bolts and nuts. Repeat for other side.

FOR ANGLE MOUNT TRACK: Complete the vertical track installation by securing the jamb bracket(s) and or tightening the other lag screws. Push the vertical track against the track rollers so that the track rollers are touching the deepest part of the curved side of the vertical track, as shown. Repeat for other side.

Top of Flag angle or Top of wallangle assembly

Door width +

3-3/8” to 3-1/2”

Nail

Top section

1-11/16” to 1-3/4”

Flag angle or wallangle assembly

Top section

Vertical track against rollers

Horizontal Tracks

Tools Required: Ratchet wrench, 9/16” 7/16” Socket, 9/16” 7/16” Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves

NOTE: Depending on your door, you may have Flag Angles or you may have Angle Mount

Vertical Track Assemblies. Refer to Package Contents / Parts Breakdown, to determine which

Flag Angles / Vertical Track Assemblies you have.

WARNING

DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SECURED AT

REAR, AS OUTLINED IN STEP, REAR BACK HANGS, OR DOOR COULD FALL

FROM OVERHEAD POSITION CAUSING SEVERE OR FATAL INJURY.

IF YOU HAVE FLAG ANGLES: To install horizontal track, place the curved end over the top track roller of the top section. Align the bottom of the horizontal track with the top of the vertical track. Tighten the horizontal track to the flag angle with (2) 1/4” - 20 x 5/8” carriage bolts and (2) 1/4” - 20 flange hex nuts.

IF YOU HAVE ANGLE MOUNT VERTICAL TRACK ASSEMBLIES: To install horizontal track, place the curved end over the top roller of the top section. Align the bottom of the horizontal track with the top of the vertical track. Tighten the horizontal track to the Flag Angle / Angle

Mount with (2) 1/4” - 20 x 5/8” carriage bolts and (2) 1/4” - 20 flange hex nuts.

Next level the horizontal track assembly and bolt the horizontal track angle to the first encountered slot in the flag angle / angle mount using (1) 3/8” - 16 x 3/4” hex head bolt and

(1) 3/8” - 16 hex nut. Repeat for other side. Next remove the nail that was temporarily holding the top section in place, installed in step, Top Section.

9

IMPORTANT: FAILURE TO REMOVE NAIL BEFORE ATTEMPTING TO RAISE DOOR COULD

CAUSE PERMANENT DAMAGE TO TOP SECTION.

Flag angle Or

Wall angle

Horizontal track

3/8”-16

Hex nut

3/8”-16 x 3/4”

Hex head bolt

Horizontal track angle

(2) 1/4”-20

Flange hex nuts

(2) 1/4”-20 x 5/8”

Carriage bolts

Flag angle Or

Wall angle

Horizontal track

Adjusting Top Fixtures

Tools Required: 7/16” / 9/16” Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves

IF YOU HAVE TOP FIXTURE BASES AND TOP FIXTURE SLIDES: With horizontal tracks installed, you can now adjust the top fixtures. Vertically align the top section of the door with the lower sections. Once aligned, position the top fixture slide, out against the horizontal track. Maintaining the slide’s position, tighten the (2) 1/4” - 20 flange hex nuts to secure the top fixture slide to the top fixture base. Repeat for other side.

Top section

Top fixture slide

Horizontal track

(2) 1/4”- 20

Flange hex nuts

Top fixture base

IF YOU HAVE TOP FIXTURE ASSEMBLIES: With horizontal tracks installed, you can now adjust the top fixtures. Vertically align the top section of the door with the lower sections.

Once aligned, position the top fixture slide, out against the horizontal track. Maintaining the top fixture slide position, tighten the (1) 5/16” - 18 nut to secure the slide to the top fixture.

Repeat for other side. Next, lock each of the top fixture slides into place using (1) 1/4” - 20 x

9/16” track bolt and (1) 1/4” - 20 hex nut through any two aligning holes.

Top section

Horizontal track

5/16”-18

Hex nut

Roller

Top section

Top fixture slide

Int. section

(1)1/4”-20 Track bolt and

(1) 1/4”-20 flange hex nut

Correct

Incorrect

End Bearing Brackets

Tools Required: Power drill, 3/16” Drill bit, Ratchet wrench, 7/16” Socket driver,

9/16” Socket, 9/16” Wrench, Tape measure, Step ladder, Safety glasses, Leather gloves

NOTE: Refer to Package Contents / Parts Breakdown, to determine which End Bearing

Brackets you have.

NOTE: Prior to fastening end bearing brackets into the door jamb, pilot drill using a 3/16” drill bit.

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING

LOOKING OUT.

NOTE: End bearing brackets are right and left hand.

Attach the left hand end bearing bracket to the left hand horizontal track angle using (2) 3/8”

- 16 x 3/4” hex head bolts and (2) 3/8” - 16 nuts. Secure the top of the end bearing bracket to the jamb using 5/16” x 2” lag screw(s), as shown. Repeat the same process for right hand side.

(2) 3/8”-16 x 3/4”

Hex head bolts

Left hand head plate / end bracket

(2) 5/16” x 2”

Lag screws

Left hand head plate / end bracket

Horizontal track angle

(2) 3/8”-16

Hex nuts

(2) 3/8”-16 x 3/4”

Hex head bolts

Horizontal track angle

Left hand head plate / end bracket

(2) 5/16” x 2”

Lag screws

Left hand head plate / end bracket

Horizontal track angle

(2) 3/8”-16

Hex nuts

Horizontal track angle

Center Bracket

Tools Required: Step ladder, Power drill, 7/16” Socket driver, 3/16” Drill bit, 1/4”

Torx bit, Level, Tape measure, Pencil, Safety glasses, Leather gloves

NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s) came with your door.

NOTE: Prior to fastening center bracket(s) into the door jamb, pilot drill using a 3/16” drill bit.

NOTE: Refer to Package Contents / Parts Breakdown, to determine if your door came with a coupler assembly. If your door came with a coupler assembly, the mounting surface needs to be a minimum of 17” wide. The two center bearing brackets will need to be spaced 12” to

14” apart at the center of the door, as shown.

NOTE: If your door came with (4) springs, each of the outer springs mounting surface will need to be a minimum of 3” wide.

NOTE: If needed, measure the diameter of your springs. If you have a one piece shaft with

3-3/4” diameter springs, they do not share center brackets and do not have a coupler assembly.

First, locate the center of the door. Mark a vertical pencil line on the mounting surface above the door, at the center. Measure from the center of the bearing, in one of the end bearing brackets, downwards, to the top the door. Using that measurement, measure that distance upwards from the top of the door to the mounting surface and mark a horizontal pencil line which intersects the vertical pencil line.

Center of head plate / end bearing bracket

Mounting surface

Vertical line

Horizontal line

Spring anchor bracket /

Center bracket

Equal distance (top of door section to horizontal line)

IF YOUR DOOR DID NOT COME WITH A CENTER COUPLER ASSEMBLY OR TORSION

SPRINGS LESS THAN 3-3/4” ID: Mark a vertical pencil line on the mounting surface above the door, at the center. Align the edge of the center bracket with the vertical pencil line and the center of the center bracket with the horizontal pencil line; this is to ensure the torsion shaft is level between the center and end bearing brackets.

NOTE: On some single spring doors, the single spring can be longer than half the opening width. If your spring is longer, then the center bracket must be mounted off center for the spring to fit properly. Measure spring length to determine appropriate center bracket location.

Mounting surface

Spring anchor bracket

/ Center bracket

Vertical line

Horizontal line

(2) 5/16” x 2”

Lag screws

(1) 5/16” x 2” Tamperresistant lag screw or (1)

5/16” x 2”Lag screw

If your door did come with a center coupler assembly or 3-3/4” ID Torsion Springs: Mark a vertical pencil line on the mounting surface above the door, at the center. Split the difference up and position the (2) center bearing brackets apart from each other. Mark two vertical pencil lines, one for each center bearing bracket onto the mounting surface above the door.

NOTE: If your door came with a center coupler assembly or if it utilizes 3-3/4” springs, the springs will not share a center bracket.

NOTE: If your door has (4) springs, split the distance between the center of the door and the end bracket on each side to locate the intermediate center brackets.

Attach each of the center bracket(s) to the mounting surface, using (2) 5/16” x 2” lag screws and (1) 5/16” x 2” tamper-resistant lag screw.

IMPORTANT: USE A 5/16” X 2” TAMPER-RESISTANT LAG SCREW INSTEAD OF THE 5/16” X

2” TAMPER-RESISTANT LAG SCREW IF MOUNTING SURFACE IS MOUNTED OVER MASONRY.

TAMPER-RESISTANT LAG SCREW MUST BE ATTACHED THROUGH THE BOTTOM HOLE OF

THE CENTER BRACKET(S).

Mounting surface

(17” Minimum)

Center of door

†

Vertical line

(2) 5/16” x 2”

Lag screws

(2) 5/16” x 2”

Lag screws

Horizontal line

† (2) Spring Anchor

Brackets / Center Brackets spaced 6” to 7” apart from the center of the door.

(1) 5/16” x 2” Tamper-resistant lag screw

10

Left hand cable drum, red

Torsion Spring Assembly

Tools Required: 3/8” Wrench, 9/16” Wrench, Step ladder, Tape measure, Safety glasses, Leather gloves

NOTE: Refer to the Package Contents and or Parts Breakdown to determine if your door came with a coupler assembly.

IMPORTANT: RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING

LOOKING OUT.

IMPORTANT: IDENTIFY THE TORSION SPRINGS PROVIDED AS EITHER RIGHT HAND WOUND

(RED WINDING CONE), WHICH GOES ON THE LEFT HAND SIDE OR LEFT HAND WOUND

(BLACK WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE.

IMPORTANT: ON SINGLE SPRING APPLICATIONS, ONLY A LEFT HAND WOUND (BLACK

WINDING CONE), WHICH GOES ON THE RIGHT HAND SIDE IS REQUIRED.

NOTE: The set screws used on all torsion winding cones and cable drums are now colored red. DO NOT identify right and left hand by the set screw color.

IF YOU DON’T HAVE A COUPLER ASSEMBLY:

Facing the inside of the door, lay the torsion shaft / torsion keyed shaft on the floor. Lay the torsion spring with the black winding cone and the black cable drum at the right end of the torsion shaft / torsion keyed shaft. Lay the torsion spring with the red winding cone and the red cable drum at the left end of the torsion shaft / torsion keyed shaft.

Slide the center bracket bearing / center bracket bushing onto the torsion shaft / torsion keyed shaft followed by the torsion springs and cable drums.

IMPORTANT: THE CENTER BRACKET BEARING / CENTER BRACKET BUSHING, TORSION

SPRINGS, AND CABLE DRUMS MUST BE POSITIONED, AS SHOWN.

Torsion shaft

Right hand cable drum, black

Left hand wound, black winding cone

(right hand side)

Spring anchor bushing / center bracket bushing

Right hand wound, red winding cone

(left hand side)

SPRING APPLICATIONS,

ONLY A LEFT HAND WOUND

(BLACK WINDING CONE),

WHICH GOES ON THE RIGHT

HAND SIDE IS REQUIRED.

With assistance, pick up the torsion spring assembly and slide one end of the torsion shaft

/ torsion keyed shaft through one end bearing bracket. Lay the middle of the torsion shaft / torsion keyed shaft into the center bracket. Slide the other end of the torsion shaft / torsion keyed shaft into the other end bearing bracket. Position the torsion shaft / torsion keyed shaft so that equal amounts of the shaft extend from each end bearing bracket.

Equal spacing

Left hand head plate

/ end bearing bracket

Right hand head plate

/ end bearing bracket

Torsion shaft

Spring anchor bushing / center bracket bushing

Spring anchor bracket / center bracket

IF YOU HAVE A COUPLER ASSEMBLY:

Disassemble the coupler assembly by removing the (3) 3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8” - 16 nylon hex lock nuts from the coupler halves. Loosen the set screws.

Set the components aside. Facing the inside of the door, lay the (2) torsion keyed shafts on the floor. One torsion keyed shaft on the left hand side and the other torsion keyed shaft on the right hand side. Starting on the left hand side, lay one of the coupler halves, the center bearing, torsion spring with the red winding cone and the red cable drum at the left end of the torsion keyed shaft. Next on the right hand side, lay the other coupler half, center bearing, the torsion spring with the black winding cone, and the black cable drum at the right end of the torsion keyed shaft.

Slide the coupler halves, center bearings onto the torsion keyed shafts followed by the torsion springs and the cable drums, as shown.

IMPORTANT: THE COUPLER HALVES, CENTER BEARINGS, TORSION SPRINGS, CABLE

DRUMS MUST BE POSITIONED, AS SHOWN.

Slide the flat edge of the couple half flush with the side edge of the torsion keyed shaft. Insert

(1) key into the slot of both the coupler half and the slot in the torsion keyed shaft. Tighten the (2) set screws and the locking nut to secure the coupler half to the torsion keyed shaft, as shown.

NOTE: Tighten the set screws to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten set screws one full turn). Repeat the same process for the other coupler half.

11

Set screws and Lock nut

Coupler halves

Black cable drum

(right hand side)

Center coupler assembly

(3) 3/8” - 16 x 1-3/4” Hex head screws and (3) 3/8” - 16 Nylon hex lock nut

Red cable drum

(left hand side)

Torsion keyed shaft

Coupler halves

Spring anchor bearing /

Center bearing

Left hand wound, black winding cone

(right hand side)

Key

Set screws and Lock nut

Spring anchor bearing /

Center bearing

Right hand wound, red winding cone

(left hand side)

Key

Coupler halves assemblied

Set screws and Lock nut

Center coupler assembly

Coupler halves

Spring anchor bearing /

Center bearing

Black cable drum

(right hand side)

Torsion keyed shaft

(3) 3/8” - 16 x 1-3/4” Hex head screws and (3) 3/8” - 16 Nylon hex lock nut

Spring anchor bearing

/ Center bearing

Coupler halves

Left wound, black winding cone

(right hand side)

Key

Red cable drum

(left hand side)

Set screws and Lock nut

Right wound, red winding cone

(left hand side)

Torsion keyed shaft

Key

Coupler halves assembled

With assistance and starting on the left hand side of door, pick up the left hand torsion spring assembly and slide one end of the torsion keyed shaft through the end bearing bracket. Lay the other side of the torsion keyed shaft into the center bracket. Repeat the same process for the right hand torsion spring assembly. Position both torsion keyed shafts so that equal amounts of the shafts extend from each end bearing brackets.

Equal spacing

Spring anchor brackets / center bearing brackets

Right hand head plate / end bearing bracket

Torsion keyed shaft

Equal spacing

Spring anchor bearing / center bracket bearing

Right hand wound, red winding cone

(left hand side)

Left hand head plate / end bearing bracket

Torsion keyed shaft

Coupler halve

Left hand head plate

/ end bearing bracket

Equal spacing

Spring anchor bushing / center bracket bushing

Right hand head plate / end bearing bracket

Torsion keyed shafts

Spring anchor bracket / center bracket

Torsion Spring Attachment

Tools Required: Step ladder, Ratchet Wrench, 9/16” Socket, 9/16” Wrench, Tape measure, Safety glasses, Leather gloves

NOTE: Refer to Package Contents / Parts Breakdown, to determine which Center Bracket(s) came with your door.

NOTE: Refer to Package Contents / Parts Breakdown, to determine if your door came with a

coupler assembly.

IMPORTANT: THE SPRING WARNING TAG(S) SUPPLIED MUST BE SECURELY ATTACHED

TO THE STATIONARY SPRING CONE(S) IN PLAIN VIEW. SHOULD A REPLACEMENT SPRING

WARNING TAG BE REQUIRED, CONTACT WAYNE DALTON FOR FREE REPLACEMENTS.

NOTE: Measure the diameter of your springs. If your spring diameter is 3-3/4”, the springs do not share center brackets. If your spring diameter is either 2” or 2-5/8”, then two springs will share the same center bracket, unless a coupler assembly is provided.

IF YOU DON’T HAVE A COUPLER ASSEMBLY:

Slide center bracket bushing into the spring. Align the stationary spring cone(s) with the holes in the center bracket bushing assembly. Secure the torsion spring(s) to the center bracket bushing assembly with (2) 3/8” - 16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts.

IF YOU HAVE A COUPLER ASSEMBLY:

Slide center bracket bushing into the spring. Align the stationary spring cone with the holes in the center bracket. Secure the torsion spring to the center bracket with (2) 3/8”-16 x 1-1/2” hex head bolts and (2) 3/8” - 16 nuts. Repeat the same process for the other center bearing bracket.

At the middle of the two center bearing brackets, re-assemble the coupler assembly by loosely fastening the coupler halves together using the (3) 3/8” - 16 x 1-3/4” hex head screws and the (3) 3/8” - 16 nylon hex lock nuts, as shown.

NOTE: Ensure both torsion keyed shafts have equal amounts of the shafts extending from each end bearing bracket.

Stationary spring cone

Spring anchor bracket

/ center bracket

Torsion spring

Stationary spring cone

Torsion spring

Spring anchor bushing / center bracket bushing

NOTE: If you have torsion keyed shaft(s), insert (1) key into the slot of both the cable drum and the slot in the torsion keyed shaft, as shown.

Rotate the left hand drum and torsion shaft until counterbalance lift cable is taut. Now attach locking pliers to the torsion shaft and brace locking pliers up against jamb to keep counterbalance lift cable taut. Repeat for right hand side.

IMPORTANT: INSPECT EACH COUNTERBALANCE LIFT CABLE MAKING SURE THEY ARE

SEATED PROPERLY ONTO THE CABLE DRUMS AND THAT BOTH COUNTERBALANCE LIFT

CABLES HAVE EQUAL TENSION.

Once the counterbalance cables are set and if applicable tighten the coupler assembly together by tightening the (3) 3/8” - 16 nylon hex lock nuts to secure the coupler halves together.

Counterbalance lift cable

Left cable drum

Left hand head plate / end bearing bracket

Counterbalance lift cable hooked in cable drum

Jamb

Left hand head plate / end bearing bracket

Locking pliers

Torsion spring

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Spring warning tag

Stationary spring cone(s)

(1) 3/8”-16 x 1-1/2”

Hex head bolt

Torsion spring

Counterbalance lift cable

Key

Left cable drum

Torsion keyed shaft

(1) 3/8”-16

Nut

(1) 3/8”-16 x 1-1/2”

Hex head bolt

Spring anchor assembly / center bracket assembly

(3) 3/8” - 16 x 1-3/4” hex head screws and

(3) 3/8” - 16 Hex nuts

Stationary spring cone

Spring anchor bracket / center bracket

Torsion spring

Coupler assembly

Coupler halves

(2) 3/8”-16 x 1-1/2” Hex head bolts and (2) 3/8”-16 Hex nuts

Torsion spring

Spring anchor bracket / center bracket

Counterbalance Lift Cables

Tools Required: Step ladder, Locking pliers, 3/8” Wrench, Tape measure, Safety glasses, Leather gloves

Starting on the left hand side, thread the counterbalance lift cable up and around the front side of the left hand cable drum.

IMPORTANT: VERIFY THAT THERE ARE NO COUNTERBALANCE LIFT CABLE OBSTRUCTIONS.

NOTE: Always assemble the left hand cable and cable drum first to help maintain equal cable tension on both sides of the door.

Hook the counterbalance lift cable into the left hand cable drum. Slide the left hand cable drum up against the left hand end bearing bracket. Counterbalance lift cable should terminate at the 3 o’clock position. Tighten the (2) set screws in the drum to 14-15 ft. lbs. of torque (once set screws contact the shaft, tighten screws one full turn).

Torsion shaft

Set screws

Chalking Torsion Spring(s)

Tools Required: Step ladder, Chalk, Safety glasses, Leather gloves

Draw a chalk line horizontally along the center of the torsion spring coil(s). As the torsion spring is wound, the chalk line will create a spiral. This spiral can be used to count and determine the number of turns that are applied on the torsion spring.

Original horizontal chalk line, prior to winding

Center bracket

Torsion spring coils

Winding cone

12

Spirals created after winding

Securing Door for Spring Winding

Tools Required: Vice clamps, Safety glasses, Leather gloves

With the door in the fully closed position, place vice clamps / c-clamps onto both vertical tracks just above the third track roller. This is to prevent the garage door from rising while winding springs.

NOTE: Check the following before attempting to wind torsion spring(s):

a. Counterbalance lift cables are secured at bottom corner brackets.

b. Counterbalance lift cables are routed unobstructed to cable drums.

c. Counterbalance lift cables are correctly installed and wound onto cable lift drums.

d. Counterbalance lift cables are taut and have equal tension on both sides.

e. Cable lift drums are against end bearing brackets and set screws are tight.

f. Torsion spring or springs are installed correctly.

g. Review the label attached to the spring warning tag, to determine number of spring turns required.

NOTE: Door MUST be closed and locked when winding or making any adjustments to the torsion spring(s).

FAILURE TO ENSURE DOOR IS IN A CLOSED POSITION AND TO PLACE

VICE CLAMP ONTO VERTICAL TRACK CAN ALLOW DOOR TO RAISE AND

CAUSE SEVERE OR FATAL INJURY.

Winding Bars

(Steel Rods)

Size Of Winding Bar

(Inches)

1/2” dia. x 18”

5/8” dia. x 24”

Spring Diameter

Used On

2” and 2-5/8”

3-3/4”

C-Clamps

6’9”

7’0”

7’3”

7’6”

7’9”

8’0”

7-1/2

7-5/8

7-7/8

8-1/4

8-3/4

Alternately inserting the winding rods into the holes of the spring winding cone, rotate the winding cone upward toward the ceiling, 1/4 turn at a time, until the required number of complete turns for your door height is achieved. As the last 1/8 to 1/4 turn is achieved, securely hold the winding rod and carefully stretch the torsion spring 1/8” - 1/4”. Next while still securely holding the winding rod, tighten both set screws in the winding cone to 14-15 ft. lbs. of torque (once set screws contact the torsion shaft, tighten screws one full turn).

Carefully remove winding rod from winding cone. Repeat for the opposite spring. While holding the door down to prevent it from raising unexpectedly in the event the spring(s) were over-wound, carefully remove the locking pliers from the torsion shaft and vertical tracks.

Adjustments to the number of turns stated may be necessary. If door rises off floor under spring tension alone, reduce spring tension until door rests on the floor. If the door is hard to rise or drifts down on its own, add spring tension.

Torsion spring(s) should be wound in the direction the end coil points.

Typical sections

Vice clamps / C-Clamps attached to inner and outer rail of vertical track

Vice clamps above third track roller on both sides of door

Bottom section

Winding Spring(s)

Tools Required: Step ladder, Approved winding bars, 3/8” Wrench, Tape measure, Safety glasses, Leather gloves

Torsion spring(s)

Spring coils

Approved winding rod

Winding cone

HIGH SPRING TENSION CAN CAUSE

SERIOUS INJURY OR DEATH.

HIGH SPRING TENSION CAN CAUSE

SERIOUS INJURY OR DEATH.

which springs are connected, such as steel brackets, cables, wood blocks, fasteners or other parts of the counterbalance system.

Adjustments or repairs must ONLY be made by a

DO NOT remove, cover or paint over this tag. Product user should inspect this tag periodically for legibility and should order a replacement tag from

Adjustments or repairs must ONLY be made by a

DO NOT remove, cover or paint over this tag. Product user should inspect this tag periodically for legibility and should order a replacement tag from

Warning tag(s)

Set screws

TAG(S) ATTACHED TO THE SPRING(S)

FOR THE REQUIRED NUMBER OF

COMPLETE TURNS, TO BALANCE

YOUR DOOR.

Torsion shaft

Approved winding rod

Rear Back Hangs

Tools Required: Ratchet wrench, Socket: 1/2” 5/8”, Wrench: 1/2” 5/8”, (2) Vice clamps, Tape measure, Level, Step ladder, Safety glasses, Leather gloves

IMPORTANT: HOLD THE DOOR DOWN TO PREVENT IT FROM RISING UNEXPECTEDLY IN THE

EVENT THE SPRING(S) WAS OVER-WOUND AND CAUTIOUSLY REMOVE VICE CLAMPS FROM

VERTICAL TRACKS.

Raise the door until the top section and half of the next section are in the horizontal track radius. Do not raise door any further since rear of horizontal tracks are not yet supported.

WINDING TORSION SPRING(S) IS AN EXTREMELY DANGEROUS PROCE-

DURE AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM

TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

USE ONLY SPECIFIED WINDING BARS, AS STATED IN STEP SECURING

DOOR FOR SPRING WINDING. DO NOT SUBSTITUTE WITH SCREWDRIV-

ERS, PIPE, ETC. OTHER TOOLS MAY FAIL OR RELEASE FROM THE SPRING

CONE AND CAUSE SERIOUS PERSONAL INJURY.

PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, EN-

SURE YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE

INSTALLATION INSTRUCTIONS. OTHERWISE THE SPRING FITTINGS MAY

RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND

COULD RESULT IN SEVERE OR FATAL INJURY.

Position a ladder slightly to the side of the spring so that the winding cone is easily accessible, and so your body is not directly in line with the winding bars.

Check the label attached to the spring warning tag for the required number of complete turns to balance your door.

Door Height

6’0”

Approximate Spring Turns

6-7/8

6’3”

6’6”

6’8”

7-1/8

7-1/4

7-3/8

RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND CAUSE

SEVERE OR FATAL INJURY.

Clamp a pair of vice clamps onto the vertical tracks just above the second track roller on one side, and just below the second track roller on the other side. This will prevent the door from raising or lowering while installing the rear back hangs.

Using the chart (Perforated Angle Gauge Weight Limitations) below, use the appropriate perforated angle (may not be supplied), (2) 5/16” x 2” hex head lag screws and (3) 5/16” bolts with nuts (may not be supplied), fabricate rear back hangs for the horizontal tracks.

Attach the horizontal tracks to the rear back hangs with 5/16” - 18 x 1” hex bolts and nuts

(may not be supplied). Horizontal tracks must be level and parallel with door within 3/4” to

7/8” maximum of door edge.

EXCEEDING THE RECOMMENDED LISTED DOOR WEIGHT LIMITATIONS OF

SPECIFIC GAUGE PERFORATED ANGLES MAY RESULT IN DOOR FALLING

WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.

VERIFY PERFORATED BACK HANG ANGLE LOAD RATINGS WITH BACK

HANG ANGLE SUPPLIER.

Perforated Angle Gauge Weight Limitations:

Perforated Angle Gauge Door Weight

13

Perforated Angle Gauge Weight Limitations:

2” x 2” x 12 Gauge Door Weight Less Than 800 lbs.

1-1/4” x 1-1/4” x 13 Gauge

1-1/4” x 1-1/4” x 15 Gauge

1-1/4” x 1-1/4” x 16 Gauge

Door Weight Less Than 305 lbs.

Door Weight Less Than 220 lbs.

Door Weight Less Than 175 lbs.

NOTE: If an opener is installed, position horizontal tracks one hole above level when securing it to the rear back hangs.

KEEP HORIZONTAL TRACKS PARALLEL AND WITHIN 3/4” TO 7/8” MAXI-

MUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING IN

SEVERE OR FATAL INJURY.

IMPORTANT: DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE REAR

BACK HANGS THAT CANTILEVERS 4” OR MORE BEYOND A SOUND FRAMING MEMBER.

NOTE: If rear back hangs are to be installed over drywall, use (2) 5/16” x 2” hex head lag screws and make sure lag screws engage into solid structural lumber.

NOTE: 26” angle must be attached to sound framing members and nails should not be used.

Now, permanently attach the weatherstrips on both door jambs and header. The weatherstrips were temporarily attached in Preparing the Opening, in the pre-installation section of this manual.

NOTE: When permanently attaching the weatherstrips to the jambs, avoid pushing the weatherstrips too tightly against the face of door.

PRIOR TO WINDING OR MAKING ADJUSTMENTS TO THE SPRINGS, EN-

SURE YOU’RE WINDING IN THE PROPER DIRECTION AS STATED IN THE

INSTALLATION INSTRUCTIONS. OTHERWISE THE SPRING FITTINGS MAY

RELEASE FROM SPRING IF NOT WOUND IN THE PROPER DIRECTION AND

COULD RESULT IN SEVERE OR FATAL INJURY.

Now, lift door and check its balance. Adjustments to the required number of spring turns stated may be necessary. If door rises off floor under spring tension alone, reduce spring tension until door rests on the floor. If the door is hard to rise or drifts down on its own, add spring tension. A poorly balanced door can cause garage door operator operation problems.

To adjust spring tension, fully close door. Apply vice grips to track above third track roller.

Insert a winding rod into the winding cone. On single spring doors, counterbalance lift cable tension must be maintained by placing vice grips on torsion shaft before loosening set screws in the winding cone. Push upward on the winding rod while carefully loosening the set screws in the winding cone. BE PREPARED TO SUPPORT THE FULL FORCE OF THE

TORSION SPRING ONCE THE SET SCREWS ARE LOOSE. Carefully adjust spring tension 1/4 turn. Retighten both set screws in the winding cone and repeat for the other side. Recheck door balance. DO NOT ADJUST MORE THAN 1/2 TURN FROM THE RECOMMENDED NUMBER

OF TURNS.

If the door still does not operate easily, lower the door into the closed position, UNWIND THE

SPRING(S) FULLY (Reference the insert “Removing The Old Door / Preparing The Opening” section on torsion spring removal) and recheck the following the items:

1.) Check the door for level.

2.) Check the torsion shaft for level.

3.) Check the track spacing.

4.) Check the counterbalance cables for equal tension and proper wrap onto the cable drums.

5.) Check the track for potential obstruction of the track rollers.

6.) Clamp locking pliers onto track and rewind springs.

IMPORTANT: IF DOOR STILL DOES NOT OPERATE PROPERLY, THEN CONTACT A TRAINED

DOOR SYSTEM TECHNICIAN.

Vice clamp

Horizontal track

5/16”-18 x 1-1/4”

Hex bolt must extend into the track to serve as a roller stop

Horizontal tracks

Sound framing members

2nd Track roller

Vice clamp

Perforated angle bolted using (2) 5/16” x 2” hex head lag screws to ceiling member and parallel to door

(3) 5/16” Bolts and nuts

Perforated angle

Sound framing members

(3) 5/16”

Bolts and nuts

Horizontal track

Perforated angle

5/16”-18 x 1-1/4”

Hex bolt must extend into the track to serve as a roller stop

Perforated angle bolted using (2) 5/16” x 2” hex head lag screws to ceiling member and parallel to door

14

3/4” To 7/8”

Door edges

Horizontal tracks

3/4” To 7/8”

15 Optional Installation

Door Arm Hookup

Align hole in the door arm with holes in drawbar operator bracket tabs, as shown. Insert

5/16” x 1-1/4” clevis pin, making sure hole in clevis pin is outside of second tab of drawbar operator bracket. Insert hairpin cotter into clevis pin hole and spread hairpin cotter to secure assembly, as shown.

Drawbar operator bracket

Cotter pin

Drawbar operator bracket tabs

Clevis pin

5/16”x 1-1/4”

Clevis pin

Door arm

Trolley Arm Configuration

Spread cotter pin

Level

High arc

Low headroom track

Top section

Typical 1/2”-1” above high arc

High arc line

Header

From step

TorqueMaster

® counterbalance

Vertical center line

FIG 3

Inside Lock

FIG 4

Measure the horizontal radius of the horizontal track to determine if you have a 12” or 15” radius horizontal track, as shown in FIG. 1; if you have a low headroom door skip this step.

Determine center line of the door. Mark vertical line at this point on the header, as shown in

FIG. 4. Raise the door slightly until the top section reaches the highest point of travel (high arc), as shown in FIG. 2 and FIG. 3 for low headroom. Using a level, mark this high arc point onto the header where it intersects the vertical center line, as shown in FIG. 4. Hold the wall bracket’s bottom edge 1/2” - 1” (room permitting) above the high arc line and centered on the vertical center line, as shown in FIG. 4. Mark the wall bracket’s mounting holes on the header wall and then refer to your garage door operator manual for pre-drilling and securing the wall bracket to header.

NOTE: Refer to your operator manual for specific details on how to assembly the curved and straight arm.

Align hole in the appropriate arm with holes in drawbar operator bracket tabs, as shown in step, Trolley Arm Hookup. Insert 5/16” x 1-1/4” clevis pin, making sure hole in clevis pin is outside of second tab of drawbar operator bracket. Insert cotter pin into clevis pin hole and spread hairpin cotter to ensure it will secure assembly.

NOTE: Depending on your door, configuration, you could have an alternative drawbar operator brackets. Refer to your alternative drawbar operator bracket insert.

Install the inside 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 inside lock should be spaced approximately 1/8” away from the section edge.

IMPORTANT: INSIDE LOCK(S) MUST BE REMOVED OR MADE INOPERATIVE IN THE UN-

LOCKED POSITION IF AN OPERATOR IS INSTALLED ON THIS DOOR.

Second section 1/8”

Square hole in vertical track

Inside lock

(4) 1/4”-20 x 11/16”

Self drilling screws

End cap

Pull Down Rope

PRIOR TO INSTALLING THE OPERATOR TROLLEY ARM TO THE DOOR,

UNPLUG THE GARAGE DOOR OPERATOR. WITH THE DOOR IN THE FULLY

CLOSED POSITION, PLACE VICE CLAMPS ONTO BOTH VERTICAL TRACKS

JUST ABOVE THE THIRD TRACK ROLLER. THIS IS TO PREVENT THE

GARAGE DOOR FROM RISING UNEXPECTEDLY WHILE INSTALLING THE

OPERATOR TROLLEY ARM TO THE DOOR. AFTER INSTALLING THE OP-

ERATOR TROLLEY ARM TO THE DOOR REMOVE THE VICE CLAMPS AND

PLUG THE GARAGE DOOR OPERATOR BACK INTO THE OUTLET.

Horizontal radius

Horizontal track

Level

High arc

Top section

WARNING

DO NOT INSTALL PULL DOWN ROPE ON DOORS WITH 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 down rope to the no. 6 screw eye and to the bottom corner bracket, as shown.

No. 6 Screw eye

Pull down rope

12” or 15”

48” to 50”

From floor

FIG 1 FIG 2

Pull down rope

Bottom corner bracket

16 Step Plate

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 than 8” 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.

Align inside step plate holes and fasten from inside using the #8 screws provided. Install one

#8 x 3/4” screw in the bottom step plate hole. 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 9405/9600

Tighten 1/4” - 20 carriage bolt and nut.

2-3/16 po

Section inférieure

Boulon de carrosserie de 1/4 po - 20 x 5/8 po

Marchepied base

Section inférieure

Amortisseur

Vis n° 8

1 po marchepied extérieur

Glissière marchepied

Écrou hexagonal Assemblées marchepied intérieur

17 Maintenance

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.

Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, a periodic washing of the garage door is recommended.

THE FOLLOWING CLEANING SOLUTION IS RECOMMENDED:

A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into five gallons of warm water will aid in the removal of most dirt.

NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.

NOTE: Be sure to clean behind weatherstrips on both sides and top of door.

or drawbar operator bracket supplied with the door. To avoid possible damage to your door,

Wayne Dalton recommends reinforcing the top section on models 8000, 8100, 8200 and

9100 doors with a strut (may or may not be supplied). The installation of the drawbar operator must be according to manufacturer’s instructions and force settings must be adjusted properly. Refer to the owner’s manual supplied with your drawbar operator for complete details on installation, operation, maintenance and testing of the operator.

MAINTAINING YOUR GARAGE DOOR…

Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. Perform routine maintenance steps once a month, and have the door professionally inspected once a year. Review your Installation Instructions and Owner’s

Manual for the garage door. These instructions are available at no charge from Wayne Dalton,

A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope, OH., 44660, or at

www.

wayne-dalton.com. For additional information on garage door/operator maintenance go to

www.dasma.com and reference TDS 151, 167 and 179.

Monthly Inspections:

1. Visual Inspection: Closely inspect jambs, header and mounting surface. Any wood found not to be structurally sound must be replaced. Inspect the springs, counterbalance lift cables, track rollers, pulleys, rear back hangs and other door hardware for signs of worn or broken parts. Tighten any loose screws and/or bolts. Check exterior surface of the door sections for any minor cracks. Verify door has not shifted right or left in the opening. If you suspect problems, have a trained door system technician make the repairs.

CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

GLASS CLEANING INSTRUCTIONS

Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.

ACRYLIC CLEANING INSTRUCTIONS

Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on particles. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will scratch the acrylic glazing. Dry glazing with a clean damp chamois.

NOTE: Do not use any window cleaning fluids, scouring compounds, gritty cloths or solventbased cleaners of any kind.

Painting Your Garage Door

Refer to Instruction Insert “

Field Painting and Finishing Fiberglass or Steel Door Sec-

tions”.

Maintaining The Finish

On Your Garage Door

If the factory finish is beginning to fade, the door may require a field applied top clear coat.

Depending on environment and usage, this may be necessary after 1 to 3 years of use. Refer to Instruction Insert “ Field Painting and Finishing Fiberglass Or Steel Door Sections”.

Operation And Maintenance

GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACK-

ETS, AND OTHER HARDWARE ATTACHED TO THE SPRINGS ARE UNDER

EXTREME TENSION, AND IF HANDLED IMPROPERLY, CAN CAUSE SEVERE

OR FATAL INJURY. ONLY A TRAINED DOOR SYSTEMS TECHNICIAN

SHOULD ADJUST THEM, BY CAREFULLY FOLLOWING THE MANUFAC-

TURER’S INSTRUCTIONS.

OPERATING YOUR GARAGE DOOR…

Before you begin, read all warning labels affixed to the door and the installation instructions and owner’s manual. When correctly installed, your Wayne Dalton door will operate smoothly.

Always operate your door with controlled movements. Do not slam your door or throw your door into the open position, this may cause damage to the door or its components. If your door has an electric opener, refer to the owner’s manual to disconnect the opener before performing manual door operation below.

Manual door operation:

For additional information on manual garage door operations go to

www.dasma.com and reference TDS 165.

IMPORTANT: DO NOT PLACE FINGERS OR HANDS INTO SECTION JOINTS WHEN OPENING

AND/OR CLOSING A DOOR. ALWAYS USE LIFT HANDLES / SUITABLE GRIPPING POINTS

WHEN OPERATING THE DOOR MANUALLY.

Opening a Door: Make sure the lock(s) are in the unlocked position. Lift the door by using the lift handles / suitable gripping points only. Door should open with little resistance.

Closing a Door: From inside the garage, pull door downward using lift handles / gripping point only or a high friction area only. If you are unable to reach the lift handles/ suitable gripping points only, use pull down rope affixed to the side of door. Door should close completely with little resistance.

Using an electric operator:

IMPORTANT: PULL DOWN ROPES MUST BE REMOVED AND LOCKS MUST BE REMOVED OR

MADE INOPERATIVE IN THE UNLOCKED POSITION.

When connecting a drawbar (trolley type) garage door operator to this door, an drawbar operator and or drawbar operator bracket must be securely attached to the top section of the door, along with any struts provided with the door. Always use the drawbar operator and

18

NEVER REMOVE, ADJUST, OR LOOSEN THE BOLTS, SCREWS AND/OR

LAG SCREWS ON THE COUNTERBALANCE (END OR CENTER BEARING

BRACKETS) SYSTEM OR BOTTOM CORNER BRACKETS OF THE DOOR.

THESE BRACKETS ARE CONNECTED TO THE SPRING(S) AND ARE UNDER

EXTREME TENSION. TO AVOID POSSIBLE SEVERE OR FATAL INJURY,

HAVE ANY SUCH WORK PERFORMED BY A TRAINED DOOR SYSTEMS

TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

TorqueMaster

Plus Springs: Pawl knob(s) (located on the TorqueMaster

end brackets above the door) should be engaged to prevent the door from rapidly descending in case of spring failure or forceful manual operation.

Torsion Springs: The torsion springs (located above the door) should only be adjusted by a trained door systems technician. DO NOT attempt to repair or adjust torsion springs yourself.

Extension Springs: A restraining cable or other device should be installed on the extension spring (located above the horizontal tracks) to help contain the spring if it breaks.

2. Door Balance: Periodically test the balance of your door. If you have a garage door drawbar operator, use the release mechanism so you can operate the door by hand when doing this test. Start with the door in the fully closed position. Lift the door to check its balance.

Adjust TorqueMaster

or Extension spring(s), if door lifts by itself (hard to pull down) or if door is difficult to lift (easy to pull down). DO NOT attempt to repair or adjust Torsion Springs yourself. To adjust TorqueMaster

or Extension spring(s), refer to your installation instructions and owner’s manual. If in question about any of the procedures, do not perform the work.

Instead, have it adjusted by a trained door systems technician.

3. Lubrication: The door should open and close smoothly. Ensure the door track rollers are rotating freely when opening and closing the door. If track rollers do not rotate freely, clean the door tracks, removing dirt and any foreign substances. Clean and lubricate (use a non-silicon based lubricant) graduated end hinges, steel track rollers and bearings. DO NOT lubricate plastic idler bearings, nylon track rollers, door track. DO NOT oil a cylinder lock, if actuation is difficult use a graphite dust to lubricate.

Warranty

Limited Warranty

Models 9100, 9405 and 9600

Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants to the original purchaser of the Models 9100, 9405 and 9600 (“Product”), subject to all of the terms and conditions hereof, that the Product and all components thereof will be free from defects in materials and workmanship for the following period(s) of time, measured from the date of installation:

LIMITED LIFETIME WARRANTY* on the Product sections against:

• Peeling, cracking, or chalking of the original factory-applied coating on the steel sections of the Product.

• The Product becoming inoperable due to rust-through of the steel skin from the core of the Product section, caused by cracking, splitting, or other deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.

• The Product hardware (except springs) and the tracks.

ONE (1) YEAR on those component parts of the Product not covered by the preceding provisions of this Warranty

*Limited Lifetime shall mean as long as the original purchaser owns the house in which the Product is originally installed.

• TWO (2) YEARS on the Model 9405 factory attached overlay material against peeling, cracking, chalking, fading or delamination

Seller’s obligation under this warranty is specifically limited to repairing or replacing, at its option, any part which is determined by Seller to be defective during the applicable warranty period. Any labor charges are excluded and will be the responsibility of the purchaser.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. This warranty is made to the original purchaser of the Product only, and is not transferable or assignable. This warranty applies only to Product installed in a residential or other non-commercial application. It does not cover any Product installed in commercial or industrial building applications. This warranty does not apply to any unauthorized alteration or repair of the Product, or to any Product or component which has been damaged or deteriorated due to misuse, neglect, accident, failure to provide necessary maintenance, normal wear and tear, acts of God, or any other cause beyond the reasonable control of Seller or as a result of having been exposed to toxic or abrasive environments, including blowing sand, salt water, salt spray and toxic chemicals and fumes.

ALL EXPRESS AND IMPLIED WARRANTIES FOR THE PRODUCT, INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS

FOR A PARTICULAR PURPOSE, ARE LIMITED IN TIME TO THE APPLICABLE WARRANTY PERIOD REFLECTED ABOVE. NO WARRANTIES, WHETHER EXPRESS OR IMPLIED,

WILL APPLY AFTER THE LIMITED WARRANTY PERIOD HAS EXPIRED. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

IN NO EVENT SHALL SELLER BE RESPONSIBLE FOR, OR LIABLE TO ANYONE FOR, SPECIAL, INDIRECT, COLLATERAL, PUNITIVE, INCIDENTAL OR CONSEQUENTIAL

DAMAGES, even if Seller has been advised of the possibility of such damages. Such excluded damages include, but are not limited to, loss of use, cost of any substitute product, or other similar indirect financial loss. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

Claims under this warranty must be made promptly after discovery, within the applicable warranty period, and in writing to the authorized distributor or installer whose name and address appear below. The purchaser must allow Seller a reasonable opportunity to inspect any Product claimed to be defective prior to removal or any alteration of its condition. Proof of the purchase and/or installation date, and identification as the original purchaser, may be required. There are no established informal dispute resolution procedures of the type described in the Magnuson-Moss Warranty Act.

• SELLER: _______________________________________________________________________

• SELLER’S ADDRESS: _______________________________________________________________________

_______________________________________________________________________

19 Thank you for your purchase.

PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE

Please Do Not Return This Product To The Store. Please call 1-866-569-3799 (Press Option 1) and follow the prompts to contact the appropriate customer service agent. They will be happy to handle any questions that you may have.

AFTER INSTALLATION IS COMPLETE, FASTEN THIS

MANUAL NEAR GARAGE DOOR FOR EASY REFERENCE.

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Key features

Torsion spring system
Standard and light commercial lift
Detailed installation instructions
Safety warnings and precautions
Step-by-step assembly guide
Maintenance and operation guidelines
Warranty information

Frequently asked questions

Door Heights less than or equal to 8’0” (< = 8’0”) are considered Standard Lift Applications. Door Heights greater than 8’0” (> 8’0”) are considered Light Commercial Applications.

You will need a power drill, vice clamps, level, drill bits, wrenches, pencil, ratchet wrench, 1/4” Torx bit, saw horses, socket driver, approved winding rods, leather gloves, sockets, hammer, safety glasses, Phillips head screwdriver, tape measure, locking pliers, step ladder.

Read all instructions and warnings carefully. Wear protective gloves to avoid cuts. Wear eye protection when using tools. Avoid installing on windy days. Use two people for doors 12’0” wide and over. Operate door only when properly adjusted. Never stand or walk under a moving door.