Wayne-Dalton 9100 User manual

325001
Use this insert in conjunction with your door’s Installation Instructions and Owner’s Manual.
(2) #12 X 1/2”
PHILLIPS HEAD SCREWS
OPPOSITE SIDE OF OPERATOR
BRACKET
FIG. 1.3
NOTE: Operator bracket must be mounted and secured prior to
installing top section.
IMPORTANT! WHEN CONNECTING A TROLLEY TYPE GARAGE
DOOR OPENER TO THIS DOOR, A WAYNE-DALTON OPENER /
TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP
SECTION OF THE DOOR, ALONG WITH ANY U-BARS PROVIDED
WITH THE DOOR. THE INSTALLATION OF THE OPENER MUST BE
ACCORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE
SETTINGS MUST BE ADJUSTED PROPERLY.
Prior to installing top section, locate the center of the top
section and seat the operator bracket on male part of top section,
align the center of both tabs of the bracket with the section’s
center line.
For retro fit applications, the operator bracket must be aligned
with an existing operator and positioned on top section so it
bridges the transition point of the section thickness, as shown in
FIG. 1.1 and 1.2.
Install (2) #12 x 1/2” phillips head screws on the opposite side of
operator bracket, as shown in FIG. 1.3.
Install top section at this time. Secure u-bar (if furnished) using
1/4” - 20 x 11/16” self-drilling screws as instructed in the door
manual and then clamp operator bracket to u-bar, as shown in
FIG. 1.4.
First attach (3) 1/4” - 14 x 5/8” self-tapping screws to the opera-
tor bracket, as shown in FIG. 1.5.
Then attach (2) 1/4” - 14 x 5/8” self-tapping screws to the opera-
tor bracket, as shown in FIG. 1.6. Remove vice clamps.
NOTE: If you have a 9100 door, you can use two of the
1/4” - 20 x 11/16” self-drilling screw used to attach the u-bar
instead of the 1/4” - 14 x 5/8” self-tapping screw when
attaching operator bracket to u-bar, as shown in FIG. 1.6.
NOTE: When attaching operator bracket to top section with u-bar,
apply additional pressure to thread the fasteners into the u-bar.
NOTE: See FIG. 1.7 for installing operator bracket on top section
without u-bars.
OPERATOR BRACKET
1
U-BAR
VICE CLAMP
NOTE: NOT REQUIRED FOR
J-STRUTS.
OPERATOR BRACKET
FIG. 1.2
U-BAR
TOP SECTION
OPERATOR
BRACKET
MALE PART OF TOP SECTION
TOP SECTION
WITH OR
WITHOUT
U-BAR
ALIGN CENTER
OF BOTH TABS
WITH CENTER
LINE OF TOP
SECTION
OPERATOR
BRACKET
FIG. 1.1
OPERATOR
BRACKET (5) TYPICAL
1/4” - 14 X 5/8”
SELF-TAPPING SCREWS
FIG. 1.7
U-BAR
(2) 1/4” - 20 X 11/16”
SELF-DRILLING SCREWS
OPERATOR
BRACKET
(2) 1/4” - 14 X 5/8”
SELF-TAPPING SCREWS
FIG. 1.6
FIG. 1.5
U-BAR
(3) 1/4” - 14 X 5/8”
SELF-TAPPING SCREWS
OPERATOR
BRACKET
REV7 05/03/2016
Trolley Arm Attachment /
Operator Bracket
Models: 9100, 9600, 5120, 5145
Installation Instructions Insert
FIG. 1.4
©Copyright 2016 Wayne Dalton, a division of Overhead Door Corporation
Wayne Dalton, a division of Overhead
Door Corporation
P.O. Box 67, Mt. Hope, OH 44660
www.Wayne-Dalton.com

2
Determine center line of door. Mark vertical line at this point, on
the header wall. Raise the door slightly until the top section
reaches the highest point of travel (high arc). Using a level, mark
this high arc point of travel on the header wall, intersecting the
vertical center line, as shown in FIG. 3.1. Hold the wall bracket’s
bottom edge typically to 1/2” - 1” (room permitting) above of the
high arc line and centered on the vertical line, as shown in FIG.
3.2.
NOTE: For standard lift and low headroom torsion
counterbalance, hold the wall bracket’s bottom edge typically
a 1/2” - 1” (room permitting) above of the torsion spring center
bracket and centered on the vertical line.
NOTE: Refer to reference illustrations in FIG. 3.3 and FIG. 3.4,
showing the difference between the standard lift and low
headroom track system.
Spot the wall brackets 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.
HIGH ARC
3
FIG. 3.1
TOP
SECTION
HIGH ARC
LEVEL
FIG. 3.2
FROM
STEP 1
HIGH ARC
LINE
HEADER
TORQUEMASTER®
COUNTERBALANCE
TYPICAL 1/2” - 1”
ABOVE HIGH ARC
VERTICAL
CENTER LINE
IDENTIFY TRACK RADIUS
2
NOTE: If you have a low headroom track system (FIG. 2.1),
proceed to Step 3.
DETERMINE THE WAYNE-DALTON TRACK RADIUS BEING USED:
FOR MOUNT HOPE AND PENSACOLA TRACK:
Measure the curved ends of the horizontal track to determine if
you have a 12” or 15” radius horizontal track, as shown in FIG.
2.2.
FOR PORTLAND TRACK:
The horizontal tracks are stamped with radius on the side of the
horizontal track, as shown in FIG. 2.3.
12”
STAMPED
RADIUS
12”
HORIZONTAL
TRACK
FIG. 2.3
FIG. 2.2
HORIZONTAL
TRACK
12” OR 15”
TYPICAL LOW HEADROOM TRACK
FIG. 2.1
TYPICAL LOW HEADROOM TRACK
FIG. 3.4
TYPICAL STANDARD LIFT TRACK
FIG. 3.3

3
Using the OPERATOR HOOK-UP CHARTS, refer to referenced
illustrations in FIG. 4.1 through FIG. 4.3 for correct arm hook-up
from trolley to operator bracket.
NOTE: Refer to your operator manual for specific details on how
to assembly the curved and straight arm, as shown in FIG. 4.1
through FIG. 4.3.
NOTE: Depending on your setup, you may have to cut straight arm
to accomplish trolley settings, as shown in FIG. 4.1 through FIG.
4.3.
FIG. 4.2
STRAIGHT ARM
CURVED ARM
CUT STRAIGHT ARM
TO ACCOMPLISH
TROLLEY SETTING
FIG. 4.1
CUT STRAIGHT ARM
TO ACCOMPLISH
TROLLEY SETTING
CURVED
ARM
STRAIGHT ARM
FIG. 4.3
STRAIGHT
ARM
OPERATOR HOOK-UP CHART FOR LOW HEADROOM
OPERATOR MODELS
TYPE OF ARM BEING USED
PREFERRED
HOOKUP
REF. ILLUSTRA-
TIONS ABOVE
OPTIONAL
HOOKUP
REF. ILLUSTRA-
TIONS ABOVE
QUANTUM/CLASSIC CURVED /
STRAIGHT FIG. 4.2 STRAIGHT FIG. 4.3
LINEAR STRAIGHT FIG. 4.3 N/A N/A
LIFTMASTER
(SEARS)
CURVED /
STRAIGHT FIG. 4.2 STRAIGHT FIG. 4.3
GENIE CURVED /
STRAIGHT FIG. 4.2 STRAIGHT FIG. 4.3
OPERATOR HOOK-UP CHART FOR LOW HEADROOM
OPERATOR MODELS
TYPE OF ARM BEING USED
PREFERRED
HOOKUP
REF. ILLUSTRA-
TIONS ABOVE
OPTIONAL
HOOKUP
REF. ILLUSTRA-
TIONS ABOVE
QUANTUM/CLASSIC CURVED /
STRAIGHT FIG. 4.2 STRAIGHT FIG. 4.3
LINEAR CURVED /
STRAIGHT FIG. 4.2 STRAIGHT FIG. 4.3
LIFTMASTER
(SEARS)
CURVED /
STRAIGHT FIG. 4.2 STRAIGHT FIG. 4.3
GENIE CURVED /
STRAIGHT FIG. 4.2 STRAIGHT FIG. 4.3
OPERATOR HOOK-UP CHART STANDARD LIFT FOR 14” AND 15” RADIUS
OPERATOR MODELS TYPE OF ARM BEING USED REF. ILLUSTRATIONS ABOVE
QUANTUM/CLASSIC CURVED / STRAIGHT FIG. 4.2
LINEAR STRAIGHT / CURVED FIG. 4.1
LIFTMASTER
(SEARS) CURVED / STRAIGHT FIG. 4.2
GENIE CURVED / STRAIGHT FIG. 4.2
TORQUEMASTER®AND EXTENSION SPRINGS
OPERATOR HOOK-UP CHART STANDARD LIFT FOR 10” AND 12” RADIUS
OPERATOR MODELS TYPE OF ARM BEING USED REF. ILLUSTRATIONS ABOVE
QUANTUM/CLASSIC STRAIGHT / CURVED FIG. 4.1
LINEAR STRAIGHT / CURVED FIG. 4.1
LIFTMASTER
(SEARS) CURVED / STRAIGHT FIG. 4.2
GENIE STRAIGHT FIG. 4.3
OPERATOR HOOK-UP CHART STANDARD LIFT FOR 14” AND 15” RADIUS
OPERATOR MODELS TYPE OF ARM BEING USED REF. ILLUSTRATIONS ABOVE
QUANTUM/CLASSIC STRAIGHT / CURVED FIG. 4.1
LINEAR STRAIGHT / CURVED FIG. 4.1
LIFTMASTER
(SEARS) CURVED / STRAIGHT FIG. 4.2
GENIE CURVED / STRAIGHT FIG. 4.2
TORSION SPRINGS
OPERATOR HOOK-UP CHART STANDARD LIFT FOR 10” AND 12” RADIUS
OPERATOR MODELS TYPE OF ARM BEING USED REF. ILLUSTRATIONS ABOVE
QUANTUM/CLASSIC CURVED / STRAIGHT FIG. 4.2
LINEAR STRAIGHT / CURVED FIG. 4.1
LIFTMASTER
(SEARS) CURVED / STRAIGHT FIG. 4.2
GENIE CURVED / STRAIGHT FIG. 4.2
OPERATOR HOOK-UP
4

4
Align hole in the appropriate arm with holes in operator bracket
tabs, as shown in FIG. 5.1.Insert 5/16” x 1-1/4” clevis pin, mak-
ing sure hole in clevis pin is outside of second tab of operator
bracket. Insert hairpin cotter into clevis pin hole and spread hair-
pin cotter to ensure it will secure assembly, as shown in FIG. 5.2.
DOOR ARM ATTACHMENT
5
DOOR ARM
TOP VIEW
HAIRPIN
COTTER
OPERATOR
BRACKET
DOOR
ARM
HAIRPIN COTTER
(OUTSIDE OF OPERATOR
BRACKET TAB)
FIG. 5.1
FIG. 5.2
5/16” X 1-1/4”
CLEVIS PIN
OPERATOR
BRACKET TABS
OPERATOR BRACKET TABS