Wayne-Dalton Torquemaster Plus 9100 Quick start guide

TorqueMaster®Plus - Single and Double Spring
Installation Instructions and Owner’s Manual
9100, 9405, AND 9600
IMPORTANT NOTICE!
Read these instructions carefully before attempting
installation. If in question about any of the proce-
dures, do not perform the work. Instead, have a
qualified door agency do the installation or repairs.
©Copyright 2015 Wayne Dalton, a Division of Overhead Door Corporation Part No. 327684 REV5 03/18/2015
Wayne Dalton, a Division of
Overhead Door Corporation
P.O. Box 67, Mt. Hope, OH 44660
www.Wayne-Dalton.com

2
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
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 QUESTION ABOUT ANY OF THE
PROCEDURES, DO NOT PERFORM THE
WORK. INSTEAD, HAVE A QUALIFIED
DOOR AGENCY DO THE INSTALLATION
OR REPAIRS.
1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.
2. Wear protective gloves during installation to avoid possible
cuts from sharp metal edges.
3. 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.
8. DO NOT stand or walk under a moving door, or permit
anybody to stand or walk under an electrically operated door.
9. 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,
red colored fasteners, 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.
After installation is complete, fasten this manual
near garage door.
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 .......................................5-9
Preparing The Opening ......................................... 10
Installation ......................................................................11-35
Optional Installations .......................................................36-44
TorqueMaster®Plus Reset Intructions..............36-38
Side Lock ............................................................. 39
DoormasterTM Bracket........................................... 39
Step Plate............................................................. 40
Pull Rope.............................................................. 41
Trolley Instructions For Standard Lift..................... 42
Trolley Instructions For Low Headroom ................. 43
Trolley Operator.................................................... 44
Maintenance....................................................................45-46
Cleaning............................................................... 45
Painting Instructions........................................45-46
Warranty............................................................................... 47
Dealer Locator Information.................................................... 48
WARNING
WARNING

3
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Package Contents
(1)TORQUEMASTER®SPRING TUBE
DOOR SECTIONS (AS REQUIRED)
(2) TOP BRACKET SLIDES
1/4”-14 X 5/8” SELF TAPPING
SCREWS (AS REQUIRED)
1/4”-20 X 11/16” SELF DRILLING
SCREWS (AS REQUIRED)
(4) 1/4”-20 X 5/8”
CARRIAGE BOLTS
(4) 1/4”-20 X 9/16” LARGE
HEAD RIBBED TRACK BOLTS
(2) VERTICAL
TRACKS RH/LH
(2) 3/8”-16 X 3/4”
TRUSS HEAD BOLTS
(1) CENTER BRACKET
ASSEMBLY
(2) FULLY ADJUSTABLE RH/LH
FLAGANGLES (AS REQUIRED)
(2) QUICK INSTALL RH/LH
FLAGANGLES (AS REQUIRED) (2) HORIZONTAL TRACKS RH/LH
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.
ROLLERS
(AS REQUIRED)
IDRIVE®OPERATOR
(SOLD SEPARATELY)
(1) OPERATOR BRACKET
(2) HORIZONTAL ANGLES
(21-15/16” OR 80”)
(AS REQUIRED)
(2) TOP BRACKET BASES
PULL ROPE
(IF INCLUDED)
5/16” X 1 5/8” HEX HEAD LAG
SCREWS (AS REQUIRED)
WEATHER SEAL & NAILS
(IF INCLUDED)
ASYMMETRICAL U-BAR
(IF REQUIRED)
TorqueMaster®- Single and Double Spring
InstallationInstructions and Owner’s Manual
9100, 9600, 5120, 5140
IMPORTANTNOTICE!
Read these instructions carefully before
attemptinginstallation. If in question about
anyof the procedures, do not perform the
work.Instead, have a qualified door agency
dothe installation or repairs.
©Copyright 2005 Wayne-Dalton Corp. PartNo. 302868 Rev.2 08/04/2005
MANUAL
1/4”- 20 FLANGED HEX
NUTS (AS REQUIRED)
U-BAR
(IF REQUIRED)
Q.I. JAMB BRACKETS
(AS REQUIRED)
DRUM WRAPS
(1) RIGHT & (1) LEFT
(2) 3/8”- 16 HEX NUTS
END BRACKETS
(1) RIGHT & (1) LEFT
WARNING
RachetBracket is under
EXTREMESPR ING TENSION.
Toavoid possib lesevere or
fatalinjury, DO NOT remove
fastenersfrom ratchet bracket
untilspring(s) are fully
wnwound.
Tosafely unwi nd spring(s)read
andfollow the directions in the
installationinstructions/owners
manual.
DONOT REMOVE THIS TAG.
P/N300547
WARNING
RachetBracket is under
EXTREMESPR ING TENSION.
Toavoid possibl esevere or
fatalinjury, DO NOT remove
fastenersfrom ratchet bracket
untilspring(s) are fully
wnwound.
Tosafely unwin d spring(s)read
andfollow the directions in the
installationinstructions/owners
manual.
DONOT REMOVE THIS TAG.
P/N300547
CABLE DRUM ASSEMBLIES
(1) RIGHT & (1) LEFT
(1) LOOSE WINDING SHAFT
(SINGLE SPRING ONLY)
(2) 5/16”HEX NUTS 5/16” X 18 X 3/4”
CARRIAGE BOLTS
(AS REQUIRED)
5/16”X 1-1/4” CLEVIS
PIN & COTTER PIN

Tools Needed:
4
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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
#1 END
HINGE
#2 END
HINGE
#3 END
HINGE
#4 END
HINGE
ASTRAGAL
BOTTOM
BRACKET
BOT. LOCK
1 3/8” 1 19/32”
INT. INT.
(USED ONLY
ON FIVE
SECTIONS)
1 1/8”
7/8”
SECTION SIDE VIEW
TYPICAL HINGE STAMPING LOCATION
Door Section Identification
TOP SECTION
INTERMEDIATE SECTION
LOCK SECTION
BOTTOM SECTION
BOTTOM BRACKET
WARNING LABELS
ASTRAGAL
#3
#2
#1
WARNING LABEL
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. The sequence
is always determined by #1 being the
bottom section to #3 or #4 being the
highest intermediate section. See views
to the right. If the stamp on the end
hinge is illegible, refer to the section
side view illustration to the right.
The section side view illustration shows
the end hinge profile of all the sections,
and can also be used in conjunction
with identifying each sections.
The BOTTOM SECTION can be
identified by #1 end hinges, the factory
attached bottom astragal, and by the
bottom bracket warning labels on each
end stile.
The LOCK SECTION can be identified
by #2 end hinge.
The INTERMEDIATE SECTION can be
identified by #3 end hinges. The section
will have a warning label attached to
either the right or left hand end stile.
NOTE: #4 End hinges are used on the
fourth section of five section doors.
The TOP SECTION can be identified
with no pre-installed end or center
hinges and U-bar attached to the top
section.

5
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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
IF YOUR COUNTERBALANCE SYSTEM IS OTHER THAN THOSE MENTIONED, DO NOT ATTEMPT TO WORK ON IT, BUT
HAVE A QUALIFIED DOOR AGENCY PERFORM THE WORK. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
DISCONNECT AND REMOVE ANY ELECTRIC OPENER PRIOR TO REMOVAL OF COUNTERBALANCE SYSTEMS TO
PREVENT UNINTENDED DOOR OPERATION. OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING ANY HARDWARE. A POWERFUL
SPRING RELEASING IT’S ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY.
IF YOU HAVE BACK PROBLEMS DO NOT ATTEMPT THIS, OR SEVERE INJURY COULD RESULT
REMOVING AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSTRUCTIONS ON PAGES 6-10 “REMOVING AN OLD
DOOR/PREPARING THE OPENING” CAREFULLY, OTHERWISE, SEVERE OR FATAL INJURY COULD RESULT.
If you have an existing door, follow the instructions to identify which counterbalance removal is necessary. The process of removing
an existing door begins by identifying it’s counterbalance system. If you are not removing an existing door, proceed to PREPARING THE
OPENING on page 10. Generally, you will find three (3) types of counterbalance systems: Extension Spring, Wayne Dalton®exclusive
TorqueMaster®and Torsion spring counterbalance systems.
For more technical information regarding the opening preparation, installation and use of your garage door and opener, you can go to
www.dasma.com and click on Publications and then Technical Data Sheet.
Tools Required
Removing An Old Door
WARNING
WARNING
WARNING
WARNING
POWER DRILL RATCHET WRENCH PLIERS/WIRE CUTTERS
PHILLIPS HEAD SCREWDRIVER PENCIL
1/8”, 3/16” DRILL BITS
FLAT TIP SCREWDRIVER
7/16” SOCKET DRIVER
TAPE MEASURE
NEEDLE NOSE PLIERS
7/16”, 1/2”, 9/16”
SOCKETS
3/8”, 7/16”, 1/2”, 9/16”
WRENCHES
SAFETY GLASSES
STEP LADDER
PRE-INSTALLATION
WARNING
VICE GRIPS VICE CLAMPS
GLOVES
(2) SAW HORSES
HAMMER

Tools Needed:
6
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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
APPROVED WINDING BAR
TORSION SPRING ASSEMBLY
WINDING CONE
SET SCREWS
FIRMLY HOLD WINDING BARS AND
CAUTIOUSLY LOOSEN SET SCREWS
P1
Approved
Winding Bars
3/8” Wrench
Vice Clamp
Recommended
tools from
page 5
FAILURE TO USE APPROVED
WINDING BARS CAN CAUSE SPRING
ENERGY TO BE RELEASED
SUDDENLY, RESULTING IN SEVERE
OR FATAL INJURY.
COUNTERBALANCE SPRING
TENSION MUST BE RELIEVED
BEFORE REMOVING ANY
HARDWARE. A POWERFUL SPRING
RELEASING IT’S ENERGY SUDDENLY
CAN CAUSE SEVERE OR FATAL
INJURY.
Do not release the torsion spring
tension unless you are qualified and
experienced door technician. Instead have
a professional door agency release the
tension.
Step 1: Close the door and place vice
clamps on the back legs of both vertical
tracks, above the third roller to prevent the
door from lifting as you unwind the springs.
Use only approved winding bars available
from your dealer. Do not use undersized
steel rods, screw drivers or anything else
to unwind the springs. Position the ladder
just off to the side of the winding cone.
The winding cone should be easy to reach
without putting your body directly in front
of it.
Step 2: Insert a winding bar into one of the
holes in the winding cone. Exert upward
pressure. Using caution, loosen the two
(2) set screws in the winding cone. Be
prepared to support the full torsional force
of the spring when the set screws are
loosened.
Step 3: Once set screws are loose, slowly
and carefully lower the winding rod until it
contacts the door. Insert other winding bar
into the upper hole. Push up and remove
lower bar. Carefully lower upper winding
bar, 1/4 turns at a time until it contacts
the door. Repeat process until all tension
is relieved. If your door is equipped with
two (2) torsion springs, follow the same
procedure to relieve tension on the second
spring.
Step 4: Remove vice clamps from tracks,
unbolt torsion shaft assembly and remove
from work area.
NOTE: Continue with “P4” on page 9 after
completing this step.
Torsion Spring Removal
For Standard Lift
WARNING
WARNING

Tools Needed:
7
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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
PRE-INSTALLATION
Fig. 2
Fig. 1
Fig. 3
RIGHT HAND
CABLE DRUM
TORQUEMASTER®
SPRING TUBE
CHECK CABLE
TENSION
LOOSEN LOCK
NUT 1/4 TURN COUNTER
GEAR/ COVER
RIGHT HAND
END BRACKET
PLACE MARK ON END BRACKET
AND DRIVE GEAR TOOTH
BEFORE UNWINDING SPRINGS
END BRACKET
RIGHT HAND
WINDING BOLT HEAD
ELECTRIC DRILL
WITH 7/16” HEX
DRIVER (DO NOT
USE IMPACT
GUN)
PRY COUNTER GEAR
AND COUNTER COVER
FROM END BRACKET
USING FLAT TIP
SCREWDRIVER
COUNTER
GEAR
COUNTER
COVER
P2
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.
For double springs, both the right hand and
left hand end brackets will always have a
drive gear, counter gear, counter cover and
a winding bolt head.
IMPORTANT: RIGHT AND LEFT HAND IS
ALWAYS DETERMINED FROM INSIDE THE
BUILDING LOOKING OUT.
Step 1: If you have a black counter
cover: Place a mark on the drive gear
tooth and an adjacent mark on the right
hand end bracket (Fig. 1). Loosen the lock
nut 1/4 turn using a 7/16” wrench and
continue with step 2.
If you have a gray counter cover: Loosen
the lock nut 1/4 turn using a 7/16” wrench
and continue with step 2.
Step 2: Using an electric drill (High torque
/ gear reduced to 1300 rpm preferred) with
a 7/16” hex head driver, unwind the right
hand winding bolt head counterclockwise
(Fig. 2) and count the number of turns the
mark on the drive gear passes the adjacent
mark on the end bracket. Referencing
the chart below, by door height, stop
unwinding the spring once the counted
turns have reached the listed number of
turns.
6’-0” Door Height = 14 turns
6’-3” Door Height = 14 1/2 turns
6’-5” Door Height = 15 turns
6’-6” Door Height = 15 turns
6’-8” Door Height = 15 1/2 turns
6’-9” Door Height = 15 1/2 turns
7’-0” Door Height = 16 turns
7’-3” Door Height = 16 1/2 turns
7’-6” Door Height = 17 turns
7’-9” Door Height = 17 1/2 turns
8’-0” Door Height = 18 turns
CAUTION: DO NOT USE IMPACT GUN TO
UNWIND SPRINGS.
IMPORTANT: DO NOT REFERENCE THE
COUNTER COVER WHEN COUNTING THE
NUMBER OF TURNS BEING UNWOUND
ON THE SPRING, BUT FOLLOW THE
INSTRUCTIONS ABOVE.
Step 3: Verify that spring tension has been
released by pulling the counterbalance
cable on the right hand cable drum away
from the header (Fig. 3). If spring tension
has been released, the cable will be loose.
In addition, the TorqueMaster®Spring Tube
TorqueMaster®Spring Removal
Recommended
tools from
page 5

Tools Needed:
8
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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
Fig. 5
Fig. 6
Fig. 7
REMOVE TOP
LAG SCREW
REMOVE
BOTTOM LAG
SCREW
USE LOCKING PLIERS
TO HOLD END BRACKET
REMOVE #10
PHILLIPS HEAD
SCREW
PRY END BRACKET FROM WINDING
SHAFT USING A FLAT TIP SCREW
DRIVER AND LOCKING PLIERS
HOLD THE
END BRACKET
STEADY WITH
LOCKING PLIERS
REMOVE CABLE DRUM AND
WINDING SHAFT
DRAPE CABLE
ACROSS
TOP OF FLAGANGLE
LIFT
TORQUEMASTER®
SPRING TUBE
OFF FLAGANGLE
CENTER
BRACKET
ASSEMBLY
(2) 5/16” X 1-5/8”
HEX HEAD LAG
SCREWS
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. 4
on previous page). Discard the counter
gear and counter cover. On double spring
applications, repeat for left hand side.
Step 5: Remove the upper 5/16” x
1-5/8” lag screw from the right hand end
bracket (Fig. 5). Attach locking pliers to
the upper portion of the end bracket and
hold the housing steady while removing
the lower 5/16” x 1-5/8” lag screw and
#10 x 1/2” phillips head screw from the
end bracket (Fig. 6).
Step 6: Holding the right hand end
bracket steady with locking pliers,
carefully pry the end bracket and drive
gear off the winding shaft using a flat tip
screwdriver (Fig. 7).
CAUTION: THE WINDING SHAFT MAY
ROTATE WHEN REMOVING THE END
BRACKET AND DRIVE GEAR.
Step 7: Repeat Step 4 for the left hand
side. Holding the left hand end bracket
steady with locking pliers, carefully pry
the end bracket off the winding shaft
using a flat tip screwdriver (Fig. 7).
Step 8: Remove the two (2) lag bolts
attaching the center bracket assembly to
the header board (Fig. 8).
Step 9: Lift the right hand side of the
TorqueMaster®Spring Tube and slide the
cable drum off. Realign the groove in the
winding shaft with the radial notch in the
flagangle and drape the counterbalance
cable with drum over the flagangle. Lift
the left hand side of the TorqueMaster®
Spring Tube and slide the cable drum
and winding shaft off (Fig. 9). Drape the
counterbalance cable with drum over the
flagangle. Lift the TorqueMaster®spring
assembly off the flagangles and out of
the doorway. Unhook the counterbalance
cables from the bottom brackets and
remove all parts from the work area.
NOTE: The cable drums may be difficult to
remove. If so, twist the cable drum to aid
in removal.
NOTE: Continue with “P4” on page 9 after
completing this step.
TorqueMaster®Spring
Removal continued...
Recommended
tools from
page 5

9
Tools Needed:
Tools Needed:
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
PRE-INSTALLATION
Removing the Old Door
Extension Spring Removal
TOP BRACKET
HINGES
HORIZONTAL TRACK
BOTTOM SECTION
(DOOR OPEN)
CAREFULLY REMOVE “S”
HOOK AND COUNTREBALANCE
CABLE (REPEAT FOR THE
OPPOSITE SIDE)
HORIZONTAL ANGLE
REMOVE LAG SCREW
FROM SAFETY CABLE (IF
INSTALLED). REPEAT FOR
OPPOSITE SIDE.
P3
P4
Recommended
tools from
page 5
Recommended
tools from
page 5
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. Remove parts
from work area.
Step 2: Holding door in the open position,
remove the vice clamps, be prepared
to support the entire weight of the door.
Garage doors can weigh 200-400 pounds.
With assistance, carefully lower the door, by
grasping the door firmly by it’s lift handles.
Do not place fingers or hands near joints,
between sections, or between bottom of
door and floor. Otherwise, severe injury
could result.
NOTE: Continue with “P4” after completing
this step.
Having removed the counterbalance
system, the door can now be
disassembled.
Start by first removing the top row of
hinges.
With assistance, hold the top section to
keep it from falling and remove the
top brackets. With assistance, lift the top
section out of the opening and remove
it from the work area. Repeat for all
remaining sections.
After door is disassembled, unbolt both
track assemblies from the jambs and
remove all material from the work area.
You can neatly dispose of the old door by
placing it in the carton of your new door.
Clean up area and complete “Preparing
the Opening” “P5” on page 10 before
installing the new door.

Tools Needed:
10
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local yellow pages/business listings or go to the Find a Dealer section online at www.Wayne-Dalton.com
HEADROOM REQUIREMENT
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.
For detailed technical information regarding the opening
preparation, refer to the DASMA Technical Data Sheet TDS
#161 “Connecting Garage Door Jambs to Building Framing”
at www.dasma.com.
The inside of your garage door opening should be framed with
wood jambs and header.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 TorqueMaster® counterbalance systems.
For low headroom applications, the jambs 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.
The jambs and header must be securely fastened to sound
framing members. Do not place jambs and header over drywall,
paneling, etc. Heads of fasteners must be flush or below jamb
and header surface, so they do not interfere with installation
or operation of new door.
TorqueMaster®counterbalance systems, a suitable mounting
surface must be firmly attached to the wall, above the header
at the center of the opening.
The mounting surface must be 2” x 6” lumber minimum (Select
southern yellow pine lumber. Do not use lumber marked as
spruce-pine-fur or SPF).
The mounting surface must be securely attached to block or
concrete wall with four (4) 3/8” masonry anchors or four (4)
5/16” x 4” lag screws for a wood structure.
NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid
splitting the lumber. Do not attach the mounting surface with
nails.
WEATHER SEAL: Cut three (3) pieces of weather seal (may not
be included) to the jambs and header.Align the jamb seals with
the inside edge of the opening. Temporarily nail the weather
seal to the jamb to keep the bottom section from falling out of
the opening during installation.
NOTE: Do not permanently attach weather seal to the jamb
at this time.
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” LHR 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.
Preparing the Opening
WARNING
TRACK TYPE TorqueMaster®
15” Radius track 11-3/4” (299 mm)
12” Radius track 10-1/2” (267 mm)
6” LHR Kit†6” (152 mm)
DOOR HEIGHT TRACK MANUAL
LIFT
MOTOR
OPERATED
6’5”, 6’6”, 7’0” 12”, 15” Radius 98”
(2489 mm)
120”
(3048 mm)
7’6”, 8’0” 12”, 15” Radius 110”
(2794 mm)
132”
(3353 mm)
WEATHER SEAL
BACKROOM REQUIREMENT
HEADROOM
BACKROOM
DOOR
WIDTH
DOOR
HEIGHT
LEVEL HEADER
PLUMB JAMBS
HEADER BOARD
2” X 6” LUMBER
PREFERRED
SUITABLE MOUNTING
SURFACE 2” X 6”
LUMBER MINIMUM
P5
Recommended
tools from
page 5
HEADER
JAMB
JAMB
QUICK INSTALL TRACK
JAMB
WEATHER
SEAL