Wayne-dalton Torque master plus 9100 Quick start guide

This Installation document is available at no charge from:

- Your local Wayne Dalton Sales Center, or

- Online at www.Wayne-Dalton.com, or

- By mailing to: Wayne Dalton, a division of Overhead Door Corporation, P.O. Box

67, Mt. Hope, OH., 44660

Table Of Contents

365455

PLEASE DO NOT RETURN THIS PRODUCT

TO THE STORE

If you need assistance, please call 1-866-

569-3799 (press Option 1) and follow the

prompts to contact a customer service

representative. They will be happy to handle

any questions that you may have.

Pre-Installation 2

Important Safety Instructions 2

Removing an Existing Door and Preparing the Opening 2

Package Contents 3

Door Section Identiﬁcation 4

Tools Required 4

Breakdown Of Parts 5

Door Installation Instructions 6

Counterbalance Installation Instructions 10

Optional Installation 15

TorqueMaster®Plus Reset Instructions 15

Door Arm Hookup 15

Trolley Arm Conﬁguration 15

Inside Lock 16

Pull Down Rope 16

Step Plate 16

Maintenance 17

Cleaning Your Garage Door 17

Painting Your Garage Door 17

Maintaining The Finish On Your Garage Door 17

Operation And Maintenance 17

Warranty 19

Wayne Dalton, a division of Overhead Door Corporation

Models 9100 / 9605

To r q u e Ma s T e r ®P l u s

InsTallaTIon InsTrucTIons and owner’s

Manual

resIdenTIal

sTandard lIfT

To avoid possible injury, read and fully understand 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.

IMPORTANT NOTICES!

Important Safety Instructions

DEFINITION OF KEY WORDS USED IN THIS MANUAL:

WARNING

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 TRAINED DOOR SYSTEMS TECHNICIAN 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, 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 instruc-

tions.

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.

18. For windloaded doors, the wind performance is achieved via the entire door system

and component substitution is not authorized without express permission by Wayne

Dalton.

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

to fastening.

CAUTION

IF ANY PART OF THE DOOR IS TO BE INSTALLED ONTO PRESERVATIVE-

TREATED WOOD, PTFE-COATED OR STAINLESS STEEL FASTENERS MUST BE

OBTAINED AND USED. REPLACEMENT FASTENERS MUST BE OF AT LEAST

EQUAL STRENGTH AND SIZE AS ORIGINAL FASTENERS. IF THE ORIGINAL

FASTENER WAS RED-HEAD, THE REPLACEMENT FASTENER MUST BE RED-

HEAD ALSO. CONTACT WAYNE DALTON FOR FASTENER STRENGTH VALUES IF

NEEDED.

WARNING

IMPACT GUNS ARE NOT RECOMMENDED. 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 DETERMINED INSIDE THE BUILDING LOOKING OUT.

Potential Hazard Effect Prevention

Moving door

WARNING

Could result in Death or Serious

Injury

Keep people clear of opening

while Door is moving.

Do NOT allow children to play

with the Door Opener.

Do NOT operate a Door that

jams or one that has a broken

spring.

High tension spring

WARNING

Could result in Death or Serious

Injury

Do NOT try to remove, install,

repair or adjust springs or

anything to which door spring

parts are fastened, such as,

wood blocks, steel brackets,

cables or other like items.

Installations, repairs and

adjustments must be done by

a trained door system techni-

cian using proper tools and

instructions.

Removing an Existing Door

and Preparing the Opening

IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE

ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.

WARNING

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.

To avoid possible injury and to insure proper installation, it's highly recommended that you

read and fully understand the complete instructions on removing an Existing Door & Prepar-

ing the Opening. These are available for download at www.Wayne-Dalton.com or at your

local Wayne Dalton Sales Center.

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 TorqueMaster®counterbalance systems. For low headroom applications, the

jambs should extend to the ceiling height. Minimum side clearance required, from the open-

ing 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 TorqueMaster®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.

Pre-Installation

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 neces-

sary) 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 sec-

tion 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.

BACKROOM REQUIREMENTS

DOOR HEIGHT TRACK MANUAL LIFT MOTOR OPERATED

6’5” to 7’0” 12”,15” Radius 98” (2489 mm) 125” (3175 mm)

7’1” to 8’0” 12”,15” Radius 110” (2794 mm) 137” (3480 mm)

HEADROOM REQUIREMENTS

TRACK TYPE SPACE NEEDED

15” Radius track 13-1/2” (343 mm)

12” Radius track 11” (279 mm)

6” LHR KIT 6” (152 mm)

Weatherstrips

Level header

Finished

Door width

Jambs

Backroom

Plumb

jambs

Finished

Door

Height

Nail

Headroom

Header board 2”x 6”

lumber preferred

Suitable mounting surface

2”x 6” lumber minimum

Weatherstrips

Jamb

Quick Install track

Other track systems

Jamb

1/8” to 1/4”

Min. Side

room

Clearance

is 3-1/2”

Min. Side

room

Clearance

is 3-1/2”

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.

Door sections (as required)

TorqueMaster

spring tube

Quick Install ﬂag angles

RH/LH (as required)

(2) Horizontal track angles (as required)

Horizontal tracks RH/LH (as required)

Vertical tracks RH/LH (as required)

Riveted vertical track assemblies RH/LH (as required)

Fully Adjustable ﬂag angles

RH/LH (as required)

Quick install jamb

brackets (as required)

Fully Adjustable jamb

brackets (as required) Left hand end

bracket (as required)

RatchetPawl

ENGAGEDSIDEVIEW

NDERNEATHVIEW

Right

hand end bracket

(2) Top ﬁxture base

s(2) Top ﬁxture slides Strut (U-shaped)

(if included) Strut (A-symmetrical)

(if included)

Cable drum

assemblies RH/LH

Drum wraps

RH/LH (optional)

Idler bracket

(single spring only)

Center bracket

bushing assembly

Weatherstrips &

nails (If included) Drawbar

operator bracket Pull down

rope (if included)

(2) 3/8”- 16 Hex nuts 1/4”- 20 Flanged

hex nuts (as required)

(2) 5/16” Washers

(2) 5/16”-18 Hex nuts

Track rollers

(as required)

5/16” x 1 5/8” Hex head lag screws

(as required) 1/4”-20 x 11/16” Self

drilling screws (as required)

(2) 5/16”-18 x 3/4”

Carriage bolts

1/4”-20 x 9/16”

Track bolts (as required)

5/16” x 1-1/4” Clevis pin Cotter pin

(2) 3/8”-16 x 3/4”

Truss head bolts 1/4”-14 x 5/8” Self tapping

screws (as required) (2) #12 x 1/2”

Phillips head screws

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, and #4

(#4 only on ﬁve section doors). 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. 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 can be identiﬁed by #3 graduated end hinges. The section

will have a warning label attached to either the right or left hand end stile.

NOTE: #4 graduated end hinges are used on the fourth section of ﬁve section doors.

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

Warning label

Intermediate section

Lock section

Bottom corner bracket warning labels

Bottom section

Bottom weather seal

Bottom corner

bracket

Bottom

weather seal

Section side view illustration

#2 Graduated

end hinge

1-1/8”

7/8”

1-3/8”

1-9/16”

Graduated

end hinge

Typical

graduated end

hinge stamping

location

Top section

Graduated

end hinge

#3 Graduated

end hinge

Tools Required

Power drill Socket driver: 7/16” Level

Drill bits: 1/8”, 3/16”,

9/32”, 7/16”, 1/2”

Ratchet wrench Tape measure Pliers / Wire cutters Flat tip screwdriver

Phillips head screwdrive

rWrenches: 3/8”, 7/16”,

1/2”, 9/16”, 5/8”

3” Ratchet

extension Sockets: 7/16”,

1/2”, 9/16”, 5/8”

Vise clamps Hammer Step ladder PencilLeather gloves

Locking pliersSafety glasses Approved winding bars

Saw horses

A. FLAG ANGLES (AS REQUIRED):

A1. Quick Install (Q.I.) Flag Angles

A2. Fully Adjustable (F.A.) Flag Angles

B. JAMB BRACKETS (AS REQUIRED):

B1. Quick Install (Q.I.) Jamb Brackets

B2. Fully Adjustable (F.A.) Jamb Brackets

C. TRACK ROLLERS (AS REQUIRED):

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 FIXTURES (AS REQUIRED):

F1. Top Fixture Bases - (L - Shaped)

F2. Top Fixture Slides - (L - Shaped)

G. STRUT(S) (AS REQUIRED):

G1. Strut (U - shaped)

G2. Strut (asymmetrical)

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

H1. Drawbar Operator Bracket

I. TRACKS (AS REQUIRED):

I1. Left Hand Horizontal Track Assembly

I2. Right Hand Horizontal Track Assembly

I3. Left Hand Vertical Track

I4. Right Hand Vertical Track

I5. Left Hand Riveted Vertical Track Assembly

I6. Right Hand Riveted Vertical Track Assembly

J. TORQUEMASTER PLUS®SPRING ASSEMBLY:

J1. Center Bracket Bushing Assembly

J2. TorqueMaster®Spring Tube (Single Or Double Springs)

J3. Left Hand End Bracket (Double Springs Only)

J4. Right Hand End Bracket (Disconnect Cable Guide)

J5. Left Hand And Right Hand Cable Drum Assemblies

J6. Idler bracket (Single Spring Only)

J7. Left Hand And Right Hand Drum Wraps (Optional)

K. REAR BACK HANGS:

K1. Left Hand And Right Hand Rear Back Hang Assemblies

A1.

A1. A2.

B1.

B2.

B1.

B2.

C1.

C2.

D1.

D2.

E4.

E1.

E2.

E3.

F1.

G1.

G2.

H1.

I4.

I2.

I1.

I3.

K1.

J3.

J4.

J1.

J6.

J5.

J2.

Lower hole

of hole/

slot pattern

3rd

hole set

Top of vertical

track

B2. (Fully

Adjustable

Feature)

2nd

hole set

1st

hole set

B1. (Quick

Install

Feature)

3rd hole

set

Top of vertical

track

2nd

hole set

1st hole

set Middle

hole

Bottom

hole

Top

hole

NOTE: The illustrations shown on this page are general

representations of the door parts. Each speciﬁc door

models may have unique variations.

J5.

J7.

A2.

I6.

I5.

F2.

F1.

F2.

BREAKDOWN OF PARTS

DOOR INSTALLATION

INSTRUCTIONS

Before installing your door, be certain that you have read and followed all of the instruc-

tions 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.

IMPORTANT: IF THE DOOR WILL BE EXPOSED TO A SIGNIFICANT AMOUNT OF ROAD SALT,

PAINT THE BARE GALVANIZED BOTTOM WEATHER STEEL RETAINER TO INHIBIT RUSTING.

Attaching Flag Angles and Jamb Brackets To

Vertical Tracks

NOTE: If you have Riveted Track or Angle Mount Track, skip this step.

FOR DOORS WITH QUICK INSTALL TRACK: Place the lower Quick Install tab of the left

hand ﬂag angle in the Quick Install feature of the left hand vertical track. Give the ﬂag angle

1/4 turn to lock in place. Measure the length of the vertical tracks. Using the jamb bracket

schedule, determine the placement of the jamb brackets for your door height and track

length. To install the jamb brackets, align the Quick Install tab on the Quick Install jamb

bracket with the Quick Install feature in the vertical track and turn the bracket perpendicular

to the track so the mounting ﬂange is toward the back (ﬂat) leg of the track. Repeat the same

process for right hand side.

JAMB BRACKET SCHEDULE

DOOR

HEIGHT

TRACK

LENGTH

1ST SET 2ND SET 3RD SET

6’0” 64”

(1626

mm)

5 M 6 B NA

6’5” 69”

(1753

mm)

3 B 6 M NA

6’8” 72”

(1829

mm)

3 B 6 M NA

7’0” 76”

(1930

mm)

3 B 7 T NA

7’3” 79” 3 B 5 B 6 B

7’6” 82”

(2083

mm)

3 B 5 B 6 B

7’9” 85”

(2159

mm)

3 B 5 B 6 B

8’0”

4-SEC

88” 3 M 6 T 7 M

8’0”

5-SEC

88”

(2235

mm)

3 B 7 T 8 T

B= BOTTOM HOLE, M= MIDDLE HOLE, T= TOP HOLE

1/4

Turn

Left hand

vertical

track

NOTE: Repeat the

same process for

the right hand side.

Left hand

ﬂag angle

1/4

Turn

Left hand

jamb bracket

Left hand

jamb bracket

3rd

Set

1st

Set

2nd Set Bottom

hole

Top

hole Middle

hole

FOR DOORS WITH FULLY ADJUSTABLE TRACK: Hand tighten the left hand ﬂag angle to

the left hand vertical track using (2) 1/4” - 20 x 9/16” track bolts and (2) 1/4” - 20 ﬂange

hex nuts.

NOTE: The bottom jamb bracket is always the shortest bracket, while the center jamb

bracket is the next tallest. If three jamb brackets per side are included with your door, you will

have received a top jamb bracket, which is the tallest.

To attach the bottom jamb bracket, locate lower hole of the hole/ slot pattern of the 1st hole

set on the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/ slot

pattern. Hand tighten jamb bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” – 20

ﬂange hex nut.

Place the center jamb bracket over the lower hole of the hole/ slot pattern that is centered

between the bottom jamb bracket and ﬂag angle of the 2nd hole set. Hand tighten jamb

bracket using (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20 ﬂange hex nut.

If a top jamb bracket was included, hand tighten it to vertical track using the lower hole of the

hole/ slot pattern in the 3rd hole set and (1) 1/4” - 20 x 9/16” track bolt and (1) 1/4” - 20

ﬂange hex nut.

(2) 1/4”- 20 x 9/16”

Track bolts

(2) 1/4”- 20

Flange hex nuts

12” Radius track15” Radius track

(2) 1/4”- 20 Flange hex nuts

Slot Slot

Left hand

ﬂag angle

Left hand

ﬂag angle

12” Or 15”

Radius

Horizontal

track

Left hand

vertical track

NOTE: Loosely fasten components

together. Repeat the same process for the

right hand side.

Left hand

ﬂag angle

Left hand

jamb bracket

Left hand

jamb bracket

3rd

Set

1st

Set

2nd

Set

1/4”- 20 x 9/16”

Track bolt

1/4”- 20

Flange hex

nut

Attaching Horizontal Track Angles

NOTE: For larger doors, a full length horizontal track angle may not already be spot welded to

the horizontal track. If the horizontal track angle is not welded, the horizontal track angle will

be installed, as shown.

Position the left hand horizontal track angle, as shown. Place the Quick Install tabs of the

horizontal track angle in the key slot of the left hand horizontal track. Using a hammer, tap

the horizontal track angle towards the curved end of the track until the alignment hole in the

track and angle are aligned. Repeat for other side. Set tracks aside.

Left hand horizontal

track angle

Key slots

Left hand

horizontal track

Quick

Install tabs

Quick Install tabs

in place

Left hand horizontal

track

Left hand horizontal

track angle

Quick

Install tabs

NOTE: Repeat the same

process for the right hand side.

Attaching Counterbalance Lift Cables and

Track Rollers

NOTE: Refer to door section identiﬁcation, located in the pre-installation section of this

manual or refer to Breakdown Of Parts.

NOTE: Cable drum assemblies are marked right and left hand.

WARNING

ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN TO PREVENT

COUNTERBALANCE LIFT CABLE FROM COMING OFF THE PIN, WHICH

COULD ALLOW THE DOOR TO FALL AND RESULT IN SEVERE OR FATAL

INJURY.

Uncoil the counterbalance lift cables from the cable drum assemblies, making sure you

place the left hand cable loop on the left hand milford pin of the bottom corner bracket and

the right hand cable loop on the right hand milford pin of the bottom corner bracket. Insert

a short stem track roller into the bottom corner brackets and another into the #1 graduated

end hinges at the top of the bottom section.

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

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.

Counterbalance

lift cable

Left hand cable

drum assembly

Counterbalance

lift cable

Bottom weather seal

Cable loop

Bottom section

Cable loop

Bottom corner

bracket warning label

Bottom corner

bracket warning label

Right hand cable drum assembly

Milford pin Milford pin

Long stem

track roller

Double graduated

end hinge

(Hinge tube)

Left hand cable

drum assembly

Bottom section

Counterbalance

lift cable

Short stem

track roller

Bottom

corner

bracket

warning

label

Bottom corner

bracket

warning label

#1 Single

graduated

end hinge

(Hinge tube)

Bottom

weather

seal

Left hand cable

drum assembly

#1 Single

graduated end

hinge (Hinge tube)

Milford

Cable

loop

Short stem

track roller

Bottom

section

Counterbalance

lift cable

Bottom

corner

bracket

Short

stem

track

roller

Positioning Bottom Section

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)

Attaching Vertical Tracks To Jambs

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.

NOTE: Make sure the counterbalance lift cable is located between the track rollers and the

door jamb.

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 and install, as shown. Drill

3/16” pilot holes into the door jamb for the lag screws.

Loosely fasten jamb brackets and ﬂag angle to the jamb using 5/16” x 1-5/8” lag screws.

Tighten lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spac-

ing, between the bottom section and vertical track. Hang counterbalance lift cable over ﬂag

angle. Repeat same process for other side.

Vertical

track

assembly

Jamb

bracket

Flag

angle

Flag angle lag screw locations

5/16” x 1-5/8”

Lag screws

Bottom

section

Track

rollers

3/8” to 5/8”

Spacing

Bottom section

15R QI12R QI

Floor Track roller

12R FA Or 15R FA

Vertical track

Attaching Strut(s) To Section

NOTE: Refer to Package Contents or Breakdown Of Parts, to determine which type of strut

you received.

IF YOUR DOOR CAME WITH A STRUT (U - SHAPED): Place the strut (U-shaped) over the

top rib of the top door section, as shown. 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.

Strut (U-shape)

(attached to top rib)

Top section

Top rib

(2) 1/4”-14 x 5/8”

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

Self tapping screws

Center line of top section

(2) 1/4”-20 x 11/16”

Self drilling screws (2) 1/4”-20 x 11/16”

Self drilling screws

6” 6”

End cap

30” To 36”

Top section

IF YOUR DOOR CAME WITH A STRUT (ASYMMETRICAL): Place the asymmetrical strut

over the top rib of the top door section, as shown. Fasten each end of the asymmetrical

strut to the end cap with (2) 1/4” - 20 x 11/16” self drilling screws. Fasten center of the

asymmetrical 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 asymmetrical 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’ asymmetrical

strut)

IMPORTANT: WHEN SECURING THE ASYMMETRICAL STRUT TO THE TOP SECTION, IT IS

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

METRICAL STRUT.

Strut

(asymmetrical)

(attached to

top rib)

Strut

(asymmetrical)

(attached to top

rib)

Long leg

Short leg

Long leg

Short

leg

Top section

Top ribTop rib

= =

(2) 1/4”-14 x 5/8”

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

Self tapping screws

Center line of top section

(2) 1/4”-20 x 11/16”

Self drilling screws (2) 1/4”-20 x 11/16”

Self drilling screws

30” To 36” 6” 6”

End cap

Top section

Attaching Drawbar Operator Bracket

NOTE: If you’re installing a drawbar operator, the drawbar operator bracket must be mounted

and secured prior to installing top section.

IMPORTANT: TO AVOID POSSIBLE DAMAGE TO YOUR DOOR, WAYNE DALTON RECOM-

MENDS REINFORCING THE TOP SECTION WITH A STRUT.

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 vise clamps. Attach (6) 1/4” - 14 x 5/8” self-tapping screws to the

drawbar operator bracket. Remove vise 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.

Top section Center line of

top section

Drawbar operator

bracket label

(2) #12 x 1/2”

Phillips head screws

1/4”- 14 x 5/8”

Self-tapping screws

Drawbar operator

bracket

Backside of

drawbar operator

bracket

NOTE: Clamp drawbar operator bracket to

strut (if supplied) with vise clamps.

Attaching Top Fixtures To Top Section

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 tap-

ping 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. Insert short stem track roller into top ﬁxture

slide. Repeat the same process for the right hand side.

NOTE: The top ﬁxture slide will be tightened and adjusted later, in step, Adjusting Top Fixture.

NOTE: Ensure the top ﬁxture slide is able to slide along the top ﬁxture base. If needed, loosen

the 1/4” - 20 ﬂange hex nuts.

(4) 1/4”- 14 x 5/8”

Self-tapping screws

Insert short stem

track roller

Top ﬁxture

base

Top ﬁxture

slide

(2) 1/4”- 20 Flange hex nuts End

cap

(2) 1/4”- 20 x 5/8”

Carriage bolts

2nd

Set

Top section

Top ﬁxture slide

Stacking Sections

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.

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 from rotating, ﬁrst secure the top middle hole of the cen-

ter 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 LEAF SECURELY AGAINST THE SECTIONS WHILE

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

BETWEEN THE HINGE LEAVES AND THE SECTIONS.

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

Intermediate

section

Lock

section

Bottom

section

Vertical

track Vertical

track

Center

hinge(s)

Center

hinge(s)

Left graduated end hinge

with short stem track roller Right graduated end hinge

with short stem track roller

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

Left double graduated

end hinge with long

stem track roller

Right double graduated

end hinge with long

stem track roller

Stacking Top Section

Place the top section in the opening. Install a nail to prevent the top section from falling

backwards. 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 must be parallel to the door sec-

tions. 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 QUICK INSTALL TRACK: Complete the vertical track installation by securing the jamb

bracket(s) and tightening the other lag screws. Repeat for other side.

FOR FULLY ADJUSTABLE TRACK OR RIVETED TRACK: Complete the vertical track instal-

lation 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.

Top section

Top

section

Nail

Door width

+ 3-3/8” to 3-1/2”

1-11/16”

to 1-3/4”

Flag

angle

Vertical track

against track rollers

Flag angle

assembly

Top of ﬂag

angle

Attaching Horizontal Tracks

NOTE: Depending on your door, you may have Quick Install Flag Angles, Fully Adjustable

Flag Angles or you may have Riveted Vertical Track Assemblies. Refer to Package Contents /

Breakdown of Parts, 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 QUICK INSTALL FLAG ANGLES: To install horizontal track, place the curved

end over the top track roller of the top section. Align key slot of the horizontal track with the

Quick Install tab of the ﬂag angle. Push curved portion of horizontal track down to lock in

place.

3/8”-16

Hex nut

3/8”-16 x

3/4” Truss

head bolt

Quick

Install

tab

Key

slot

Quick

Install

tab in

place

Level

Horizontal track angle

Flag

angle

upper

slot

Flag

angle

Horizontal

track

FOR OTHER 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 verti-

cal track. Tighten the horizontal track to the ﬂag angle with (2) 1/4” - 20 x 9/16” track bolts

and (2) 1/4” - 20 ﬂange hex nuts.

3/8”-16

Hex nut

Horizontal

track angle

3/8”-16 x 3/4”

Truss head bolt

1/4”-20 x 9/16”

Track bolts

1/4”-20 Flange

hex nuts

Horizontal

track

Flag angle

upper slot

Level

1/4”-20 x 9/16”

Track bolts

1/4”-20 Flange

hex nuts

12” Radius

track

15” Radius track

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” truss head bolt

and (1) 3/8” - 16 hex nut. Repeat for other side. Remove nail that was temporally holding the

top section in position.

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

CAUSE PERMANENT DAMAGE TO TOP SECTION.

Horizontal

track

Level

Horizontal

track angle

Horizontal

track angle

Horizontal

track

Adjusting Top Fixtures

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 ﬁxture

slide

Tighten the (2)

1/4”- 20

Flange hex nuts

Horizontal

track

Top section

Top ﬁxture

base Intermediate

section

Track roller

Top

section

Top

section

COUNTERBALANCE

INSTALLATION INSTRUCTIONS

Preparing The TorqueMaster®Spring Tube

Assembly

NOTE: TorqueMaster®springs come lubricated and pre-assembled inside the TorqueMaster®

spring tube.

To prepare for install, lay the spring tube assembly on the ﬂoor, inside garage, in front of the

door, and with the labeled end to the left. Next, remove the shipping boots from the ends of

the TorqueMaster® spring tube.

Being cam shaped, the center bushing only ﬁts one way. Slide the center bracket bushing as-

sembly towards the center of the TorqueMaster® spring tube, from the right side, as shown.

NOTE: Refer to Package Contents / Breakdown of Parts, to determine if you have drum

wraps (optional).

Drum wraps (optional) are marked right and left hand. Beginning with the left hand side, slide

the left hand drum wrap onto the TorqueMaster®spring tube. Repeat for the right hand side.

The drum wrap will be secured later, in Step, Securing Drum Wraps.

TorqueMaster®spring

tube

Remove shipping

boots and discard.

Label

Left hand drum

wrap (Optional) Right hand

drum wrap

(Optional)

Label

TorqueMaster®

spring tube

TorqueMaster®

spring tube

Center

bracket

NOTE: Orient proﬁle of

spring tube and center

bracket hole for smooth ﬁt.

Installing Cable Drum Assemblies

NOTE: Cable drum assemblies are marked right and left hand. Cable drums and TorqueMas-

ter®spring tube assembly are cam shaped to ﬁt together only one way.

Shake the TorqueMaster®spring tube assembly gently to extend the winding shafts out about

5” on each side. For single spring applications, there will be no left hand spring in the

TorqueMaster®spring tube assembly. Lift the TorqueMaster®spring tube assembly and rest it

on top of the ﬂag angles.

NOTE: Temporarily support the center of the TorqueMaster®spring tube assembly until the

center bracket is installed in Step Attaching Center Bracket to Wall.

5”

Center

bracket

Winding

shaft

Winding

shaft

Winding

shaft

Winding

shaft

TorqueMaster®

spring tube

Center

bracket

Label

TorqueMaster®spring tube

TorqueMaster®

spring tube

NOTE: For single spring applications,

there will be no left hand spring in the

TorqueMaster®spring tube assembly.

NOTE: If winding shaft is not visible out

of the right hand side, gently shake the

TorqueMaster®spring tube until

winding shaft sticks out 5”.

NOTE: If both winding shafts are

not visible, gently shake the

TorqueMaster®spring tube until

both winding shaft sticks out 5”.

Left hand

cable

drum

assembly

Right hand cable

drum assembly

NOTE: Working with a partner as needed, lift

the TorqueMaster®spring tube assembly up

and rest it on top of the ﬂag angles.

Flag angle

Flag

angle

Center

bracket

Label

NOTE: Cable drum assemblies are marked right and left hand. Cable drums and TorqueMas-

ter®spring tube assembly are cam shaped to ﬁt together only one way.

Starting on the right hand side, pre-wrap the cable drum with the counterbalance lift cable

1/2 wrap, as shown. Position the TorqueMaster®spring tube assembly so the cam peak

is pointing straight up. Slide the cable drum over the winding shaft until the cable drum

seats against the TorqueMaster®spring tube assembly. The winding shaft must extend past

the cable drum far enough to expose the splines and the grooves. Align the winding shaft

grooves with the round notch in the ﬂag angle.

Right hand

cable drum

Right

hand

cable

drum

TorqueMaster®

spring tube

assembly

Counterbalance

lift cable 1/2

wrap

Counterbalance

lift cable

Winding

shaft

Cam peak

straight up

Splines

Groove

Round notch

in ﬂag angle

5” Winding

shaft

Cam

peak

straight

Insert winding

shaft into ﬂag

angle

Bearing

FOR DOUBLE SPRING APPLICATIONS: Repeat for left hand side.

Left hand

cable drum

TorqueMaster®

spring tube

assembly

Counterbalance lift

cable 1/2 wrap

Counterbalance

lift cable

Winding

shaft

5”

Left hand

cable drum

Splines

Groove

Round notch

in ﬂag angle

Winding

shaft

Cam

peak

straight

Insert winding

shaft into ﬂag

angle

Bearing

FOR SINGLE SPRING APPLICATIONS: Insert the idler bracket into the left hand cable drum.

Lightly press the idler bracket into the cable drum until two distinct clicks are heard, or the

bracket is inserted all the way.

IMPORTANT: ENSURE THE SNAPS ON THE IDLER BRACKET (LEFT HAND SIDE) ARE EN-

GAGED INTO THE LEFT HAND CABLE DRUM, SO THAT IT DOES NOT COME BACK OUT.

NOTE: The idler bracket is designed for permanent assembly. Do not attempt to remove idler

bracket once inserted into the cable drum.

NOTE: The idler bracket must extend past the cable drum far enough to expose the groove.

Align the idler bracket groove with the round notch in the ﬂag angle.

Left hand

cable drum

TorqueMaster®

spring tube

assembly

Counterbalance lift

cable 1/2 pre-wrap

Counterbalance

lift cable

Idler

bracket

Cam peak

straight up

Round

notch

Groove

Flag

angle

Snaps Idler

bracket

Flag

angle

Bearing

Idler

bracket Snaps

Groove

Left hand

cable drumIdler

bracket Snaps

Groove

Left

hand

cable

drum

Attaching End Brackets To Flag Angles

IMPORTANT: WARNING TAGS MUST BE SECURELY ATTACHED TO END BRACKET(S).

IMPORTANT: FOR SINGLE SPRING DOORS, ENSURE THE LEFT HAND CABLE DRUM BEARING

IS ALL THE WAY TO THE LEFT AND UP AGAINST THE FLAG ANGLE. IF THE CABLE DRUM IS

PULLED AWAY FROM THE FLAG ANGLE, THEN THE IDLER BRACKET CAN RUB AGAINST THE

CABLE DRUM CAUSING NOISE.

NOTE: Drill 3/16” pilot holes into header for the lag screws.

Beginning with the right hand side, slide the end bracket onto the winding shaft so that the

splines in the ratchet wheel ﬁt onto the winding shaft grooves. Attach the end bracket to the

ﬂag angle using (1) 5/16” - 18 x 3/4” carriage bolt, (1) 5/16” washer and (1) 5/16” - 18 hex

nut. Then secure the end bracket to the jamb using (1) 5/16” x 1-5/8” lag screw.

NOTE: If ratchet wheel falls out of end bracket, refer to illustration for proper insertion

orientation.

FOR DOUBLE SPRING APPLICATIONS: Repeat same process for left hand end bracket.

Grooves

Warning

tag

Disconnect cable

guide hole

Splines

Winding

shaft

Right

hand

end

bracket

Flag

angle

TorqueMaster®

spring tube

assembly

Right hand

cable drum

Ratchet wheel

(oriented correctly)

FOR DOUBLE SPRING

APPLICATIONS:

Repeat

same process for left

hand end bracket.

5/16”

Washer

5/16”

Hex nut

Winding

shaft

5/16” -18 x 3/4”

Carriage bolt

TorqueMaster®

spring tube

assembly

Right hand

cable drum

5/16” x 1-5/8”

Lag screw

Right

hand end

bracket

Flag

angle

Flag

angle

FOR SINGLE SPRING APPLICATIONS: Secure the idler bracket to the ﬂag angle using (1)

5/16” - 18 x 3/4” carriage bolt, (1) 5/16” washer and (1) 5/16” - 18 hex nut. Then secure

the idler bracket to the jamb using (1) 5/16” x 1-5/8” lag screw.

TorqueMaster®

spring tube

assembly

Left hand

cable drum

Idler bracket

Flag

angle

5/16” x 1-5/8”

Lag screw

5/16” -18 x 3/4”

Carriage bolt

5/16” Washer

5/16” Hex

nut

Flag

angle

Left hand

cable drum

Bearing

Attaching Center Bracket to Wall

IMPORTANT: TORQUEMASTER®SPRING TUBE MUST BE LEVEL BEFORE SECURING CENTER

BRACKET BUSHING ASSEMBLY TO HEADER.

NOTE: Drill 3/16” pilot holes into header for the lag screws.

To locate the center bracket bushing assembly, mark the header halfway between the ﬂag

angles and level the TorqueMaster® spring tube. Fasten the center bracket bushing assem-

bly to the header using (2) 5/16” x 1-5/8” lag screws.

TorqueMaster® spring tube

Center bracket

bushing assembly

Level

(2) 5/16” x 1-5/8”

Lag screws

Securing Door For Winding Spring(s)

With the door in the fully closed position, place locking pliers onto both vertical tracks just

above the third track roller. This is to prevent the garage door from rising while winding

spring(s).

NOTE: Check the following before attempting to wind 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. TorqueMaster®spring tube is installed correctly.

e. 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

spring(s).

WARNING

FAILURE TO PLACE LOCKING PLIERS ONTO VERTICAL TRACK CAN

ALLOW DOOR TO RAISE AND CAUSE SEVERE OR FATAL INJURY.

Locking pliers above

third track roller on

both sides of door

Bottom section

Lock

section

Locking pliers attached

to inner and outer rail

of vertical track

Intermediate section

Vertical

track Vertical

track

Adjusting Counterbalance Lift Cable

Starting on the right side, adjust the cable drum assembly by rotating the drum until the set

screw faces directly away from the header. The position of the cam peak on the TorqueMas-

ter®spring tube should be pointing straight up.

Loosen the set screw no more than 1/2 turn. Ensure counterbalance lift cable is aligned and

seated in the ﬁrst and second grooves of the cable drum. Pull on the end of the cable to

remove all cable slack.

Snug the set screw and then tighten an additional 1-1/2 turns. Measure approximately 6” of

cable and cut off excess cable. Insert end of the cable into the hole of cable drum. Repeat for

left hand cable drum assembly.

IMPORTANT: ENSURE THE COUNTERBALANCE LIFT CABLE IS SEATED IN THE FIRST

GROOVE OF THE CABLE DRUM PRIOR TO WINDING SPRINGS.

Cam peak

pointing straight up

Insert

cable here

6”

Cut cable here

Tighten

set screw

TorqueMaster®

spring tube

Counterbalance

lift cable

Insert

cable here

First

groove

NOTE: Illustration shows the right hand cable drum assembly. Repeat the same process for

the left hand side.

Winding Spring(s)

IMPORTANT: VERIFY THAT THERE ARE NO OBSTRUCTIONS IN THE TRAVEL PATH OF THE

DOOR SECTIONS OR COUNTERBALANCE LIFT CABLES.

IMPORTANT: INSPECT EACH COUNTERBALANCE LIFT CABLE MAKING SURE IT IS SEATED

PROPERLY ONTO THE CABLE DRUM AND THAT BOTH COUNTERBALANCE LIFT CABLES HAVE

EQUAL TENSION.

PRIOR TO WINDING SPRING(S), CHECK COUNTERBALANCE LIFT CABLES FOR EQUAL

TENSION:

1. Attach locking pliers to track above top roller.

2. Grasp cable at approximate mid-door height location.

3. Draw cable toward you about 1/2” to 1” and release, noting the response of the cable.

4. Repeat above steps for other cable.

5. Adjust cable tension as needed until right and left cables both respond the same.

WARNING

WINDING SPRING IS AN EXTREMELY DANGEROUS PROCEDURE

AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM

TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

WARNING

IT IS RECOMMENDED THAT LEATHER GLOVES BE WORN WHILE WINDING

SPRINGS. FAILURE TO WEAR GLOVES MAY CAUSE INJURY TO HANDS.

NOTE: A 3” ratchet extension is recommended for added clearance from the horizontal track

angle.

IMPORTANT: PAWL KNOB MUST BE IN UPPER POSITION TO ADD / REMOVE REQUIRED

NUMBER OF SPRING TURNS.

There are two methods for counting the spring turns as you wind. One method is to identify

the black tooth on the ratchet wheel inside of the end bracket. When the wheel makes one

revolution and the tooth returns to its starting point, one turn has been made. The other

method is to make a mark on the winding shaft (or socket) and end bracket, and count your

turns in this manner.

Check the label attached to the spring warning tag or the Winding Spring Turn Chart (below)

for the required number of complete turns to balance your door.

Starting on the right hand side, turn the pawl knob on the end bracket to the upper position.

Using a ratchet wrench with a 5/8” socket and a 3” ratchet extension, wind the spring by

rotating the winding shaft counter clockwise, while watching either the black tooth on the

ratchet wheel or the mark on the winding shaft. After 2 to 3 turns, remove the ratchet wrench

and adjust the counterbalance lift cable on the left side. Ensure counterbalance lift cables are

in the ﬁrst groove of the cable drums, as shown in Step Adjusting Counterbalance Lift Cable.

NOTE: Single spring applications require no spring winding on the left hand side, but lift

cable tension needs to be adjusted.

FOR SINGLE SPRING APPLICATIONS: Return to the right hand end bracket and continue

winding the spring to the required number of turns for your door following the double spring

instructions below. Place pawl knob in lower position.

FOR DOUBLE SPRING APPLICATIONS: Either use the black tooth on the ratchet wheel for

winding reference or place a mark on the winding shaft and end bracket. Place the ratchet

wrench with 5/8” socket and a 3” ratchet extension onto the left hand winding shaft end.

To wind the spring, rotate the winding shaft clockwise, while watching the black tooth on

the ratchet wheel or the mark on the winding shaft. Rotate the winding shaft to the required

number of winding turns for your door. Then return to the right hand side and wind the right

hand spring to the required number of turns. Place pawl knob in lower position on both sides.

IMPORTANT: MARK THE NUMBER OF SPRING TURNS ONTO THE END BRACKET WARNING

TAG.

WINDING SPRING TURN CHART

DOOR HEIGHT SPRING TURNS

6’-0” 14

6’-3” 14-1/2

6’-5” - 6’-6” 15

6’-8” - 6’-9” 15-1/2

7’-0” 16

7’-3” 16-1/2

7’-6” 17

7’-9” 17-1/2

8’-0” 18

NOTE: Since total turns to balance door can deviate from winding spring turn chart values by

± 1 turn, adjustments to the recommended number of turns may be required after rear back

hangs are installed.

Counterbalance

lift cable

Right hand

end bracket

Pawl knob

in upper

position

5/8”

Socket

Ratchet

wrench

Winding

shaft 3” Ratchet

extension

Marks

Counterbalance

lift cable Left hand

end bracket

Pawl knob

in upper

position

5/8”

Socket

Ratchet

wrench

3”

Extension

Marks

Winding

shaft

Securing Drum Wraps (Optional)

NOTE: If you don’t have drum wraps, then skip this step. Refer to Package Contents / Break-

down Of Parts, to determine if you have drum wraps.

Starting on the left hand side, position the left hand drum wrap, as shown. Slide the left hand

drum wrap over the cable drum assembly.

IMPORTANT: PULL THE COUNTERBALANCE LIFT CABLE AWAY FROM THE HEADER TO

CLEAR THE LATCH, WHILE SIMULTANEOUSLY SLIDING THE DRUM WRAP AGAINST THE LAST

RIB UNTIL THE THREE CATCHES ENGAGE THE 3RD RIB.

Secure the hinge latch by rotating upward until a distinct snap is felt. Conﬁrm the catch is

fully engaged by lightly tugging on it. Repeat the same process for right hand side.

Left hand

drum wrap

Cable

drum

Re-engage

hinged latch

3rd rib

Counterbalance lift

cable. Pull to clear latch

Left hand

drum wrap

Catches

Left hand

drum wrap

Last

rib

NOTE: Repeat the same process for right

hand side.

Attaching Rear Back Hangs

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

EVENT THE SPRING(S) WERE OVER-WOUND AND CAUTIOUSLY REMOVE LOCKING PLIERS

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.

WARNING

RAISING DOOR INTO THE LOOSE HORIZONTAL TRACKS CAN RESULT IN

DOOR FALLING AND CAUSE SEVERE OR FATAL INJURY.

Clamp a pair of locking pliers 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 below, select the appropriate perforated angle (may not be supplied). Fabri-

cate and install rear back hangs, as shown.

Perforated Angle Gauge Weight Limitations:

Perforated Angle Gauge Door Balance Weight

2” x 2” x 12 Gauge 800 lbs. to 1600 lbs.

1-1/4” x 1-1/4” x 13 Gauge 305 lbs. to 610 lbs.

1-1/4” x 1-1/4” x 15 Gauge 220 lbs. to 440 lbs.

1-1/4” x 1-1/4” x 16 Gauge 175 lbs. to 350 lbs.

NOTE: If an opener is installed, position horizontal tracks one hole above level when securing

them to the rear back hangs.

WARNING

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

MAXIMUM OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTING

IN SEVERE OR FATAL INJURY.

WARNING

MAKE SURE BACK HANGS ARE BRACED SUFFICIENTLY TO RESIST ANY

MOTION DURING SPRING APPLICATION AND DOOR TRAVEL. IF BACK

HANGS PIVOT OR DEFLECT, ADD REINFORCEMENT UNTIL THEY REMAIN

FIRM AND STATIONARY. ANY BACK HANG THAT HAS BENT MUST BE

REPLACED.

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.

WARNING

FAILURE TO ASSEMBLE AND ATTACH REAR BACK HANGS PROPERLY

ACCORDING TO THE ABOVE INSTRUCTIONS MAY RESULT IN DOOR

FALLING WHEN RAISED, CAUSING SEVERE OR FATAL INJURY.

NOTE: Perforated angle must be attached to sound framing members and nails should not

be used.

90°

(3) 5/16”

Bolts and nuts

(3) 5/16” Bolts and

(3) 5/16” nuts

Perforated

angle

5/16” Hex nut

5/16”-18 x 1-1/4”

Hex bolt

Perforated angle bolted

using (2) 5/16” x 1-5/8”

hex head lag screws to

ceiling member and

parallel to door

Horizontal track

NOTE: Repeat the same

process for right hand side.

Horizontal tracks

Door edges

3/4” To 7/8”

Attaching Weather Seal

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 weath-

erstrips too tightly against the face of door.

Weather seals

Nail

Weather

seal

Jamb Weather seal

installed

Jamb

Header

Jamb

Nail

NOTE: Door not shown for clarity.

Balancing Door

NOTE: Windows may cause the top section to be signiﬁcantly heavier than the remaining

sections. Wayne Dalton attempts to balance the door at the top and bottom. To prevent any

sudden door acceleration between the top and bottom, we recommend motor operating all

doors with windows.

Remove any locking pliers. Lift the door and check its balance. Adjust spring(s) if door lifts by

itself (hard to pull down) or if door is difﬁcult to lift (drifts down). Anytime spring adjustments

are made, ratchet pawl knob must be in the upper position. An unbalanced door can cause

TorqueMaster®Plus operation problems.

Close the door and place locking pliers onto both vertical tracks just above the third track

roller. This is to prevent the garage door from rising while adjusting the spring(s).

IMPORTANT: TO ADJUST SPRINGS, ONLY ADD OR REMOVE A MAXIMUM OF 3/10 OF

A TURN (THREE TEETH ON THE RATCHET WHEEL) AT A TIME. BOTH SIDES NEED TO BE

ADJUSTED EQUALLY ON DOUBLE SPRING DOORS.

WARNING

WINDING SPRINGS IS AN EXTREMELY DANGEROUS PROCEDURE

AND SHOULD BE PERFORMED ONLY BY A TRAINED DOOR SYSTEM

TECHNICIAN USING PROPER TOOLS AND INSTRUCTIONS.

ADD SPRING TENSION: The ratchet wheel is made of 10 teeth. To add spring tension,

tighten counter clockwise on the right hand side and clockwise on the left hand side. Place

pawl knob in upper position. Place the ratchet with 5/8” socket and 3” ratchet extension

onto the winding shaft, to add 3/10 of a turn. Watch as three teeth of the ratchet wheel pass

over the pawl, creating three “clicks”. Place pawl knob in lower position. For double spring

applications, repeat the same process for the other side.

REMOVE SPRING TENSION: To remove spring tension, place a regular 5/8” wrench onto the

winding shaft. Place pawl knob in upper position.

IMPORTANT: BE PREPARED TO HOLD THE FULL TENSION OF THE SPRING.

Pull down on the wrench to relieve pressure between the pawl and the ratchet wheel. Push in

on the pawl to allow the three ratchet wheel teeth to pass by the pawl, as you carefully allow

the wrench to be rotated upward by the spring tension, release the pawl to allow it to engage

with the ratchet wheel. Place pawl knob in lower position. For double spring applications,

repeat the same process for the other side.

IMPORTANT: DO NOT ADD OR REMOVE MORE THAN 1 SPRING TURN (1 SPRING TURN

EQUALS 10 TEETH ON RATCHET WHEEL) FROM THE RECOMMENDED NUMBER OF TURNS

SHOWN ON THE WINDING SPRING TURN CHART.

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

spring(s) completely, and recheck the following items:

1.) Is the door level?

2.) Are the TorqueMaster®spring tube and ﬂag angles level and plumb?

3.) Does the distance between the ﬂag angles equal door width plus 3-3/8” to 3-1/2”?

4.) Do the counterbalance lift cables have equal tension? Adjust if necessary.

5.) Rewind the spring(s).

6.) Make sure door is not rubbing on jambs.

Ratchet

wrench

End bracket

Pawl

Winding

shaft

Ratchet wheel

Pawl knob in

lower position

Pawl knob in

upper position

Pawl

3”

Ratchet

extension

5/8” Socket

TorqueMaster®Plus Reset Instructions

IMPORTANT: THE DRAWBAR OPERATOR FORCE SETTINGS MUST BE ADJUSTED AC-

CORDING TO THE MANUFACTURER’S INSTRUCTIONS. SOME LIGHTER WEIGHT DOORS ARE

DESIGNED TO OPERATE WITH A SINGLE COUNTERBALANCE SPRING. IF THAT COUNTER-

BALANCE SPRING BREAKS AND THE DRAWBAR OPERATOR’S FORCE SETTINGS ARE NOT

ADJUSTED ACCORDING TO THE MANUFACTURER’S SPECIFICATIONS, THE DRAWBAR

OPERATOR MAY THEN HAVE THE CAPABILITY OF LIFTING THE DOOR TO THE OPEN POSI-

TION, DESPITE THE BROKEN COUNTERBALANCE SPRING. THIS SCENARIO WILL CAUSE

THE COUNTERBALANCE LIFT CABLES TO GO SLACK AND ENGAGE THE TORQUEMASTER®

PLUS SAFETY SYSTEM. IF A PERSON IS UNAWARE OF THE SLACK COUNTERBALANCE LIFT

CABLES AND THE ENGAGED TORQUEMASTER®PLUS SAFETY SYSTEM AND ACTIVATES THE

MISADJUSTED DRAWBAR OPERATOR, DAMAGE WILL LIKELY OCCUR TO THE DOOR AND

DRAWBAR OPERATOR. THE POTENTIAL ALSO EXISTS THAT THE PERSON ACTIVATING THE

DRAWBAR OPERATOR UNDER THIS SCENARIO COULD BE SEVERELY INJURED.

WARNING

READ THESE INSTRUCTIONS CAREFULLY BEFORE ATTEMPTING TO

RESET THE TORQUEMASTER® PLUS SYSTEM. IF IN QUESTION ABOUT

ANY OF THE PROCEDURES, DO NOT PERFORM THE WORK. INSTEAD,

HAVE A QUALIFIED DOOR SYSTEMS TECHNICIAN RESET THE SYSTEM.

WARNING

TO AVOID SEVERE OR FATAL INJURY, DO NOT STAND OR WALK UNDER

A MOVING DOOR, OR PERMIT ANYONE TO STAND OR WALK UNDER AN

ELECTRICALLY OPERATED DOOR.

This door is equipped with a TorqueMaster®plus system, a safety feature which prevents

the door from rapidly descending in case of spring failure or forceful manual operation. If the

system engages with the door in the open position, personal items that are left unattended in

the garage or home are at risk to theft. To ensure the safekeeping of these items, close the

garage door.

Typical signs of an engaged system.

Single spring system: Visually inspect the TorqueMaster®Plus right hand end bracket to

conﬁrm that the system has engaged (see illustration). If the system is engaged, then the

door will not close. If the drawbar operator force settings were properly set during the initial

installation, the door will not open. If the drawbar operator can physically overcome the

weight of the door and lift it to the open position, then the counterbalance lift cables will be

slack. If the system is engaged, DO NOT attempt to make the repairs. Instead, have a trained

door system technician make the necessary repairs to counterbalance lift cables, spring

assemblies and other hardware.

Double spring system: Visually inspect the TorqueMaster®Plus end brackets to conﬁrm

that the system has engaged (see illustration). Door makes a distinct “clicking” noise upon

being opened. If the system is engaged, carefully follow the reset instructions below or refer

to the reset tag (attached to right hand end bracket) to reset the TorqueMaster®Plus system.

Resetting an engaged TorqueMaster®Plus double spring system only:

1. First, locate and visually inspect the TorqueMaster®plus end bracket(s) to conﬁrm that the

system has engaged (see illustration).

2. With the door in the fully closed position, place locking pliers onto both vertical tracks just

above the third track roller. Disengage the drawbar operator (if installed) by pulling or placing

the emergency disconnect in the manually operated position.

3. With assistance, carefully remove locking pliers and raise the door to the fully open posi-

tion.

4. Place locking pliers onto both vertical tracks just below the bottom track roller on both

sides.

5. Now is a good time to remove vehicles or personal items from garage to provide clear

access to end brackets.

6. For single spring applications: Flip the ratchet pawl knob on the right hand end bracket

to the upper position. For double spring applications: Flip the ratchet pawl knob on both

end brackets to the upper position (see illustration).

7. Raise door 2”-3” and then lower door. Repeat this process until the system resets (see

disengaged system illustrations).

IMPORTANT: BE PREPARED TO SUPPORT THE TOTAL WEIGHT OF THE DOOR.

8. Cautiously remove the locking pliers from the vertical tracks. With assistance lower door.

Checking springs for tension:

9. Starting on the right hand side, place a ratchet wrench, 5/8” socket and a 3” extension

on the TorqueMaster®Plus winding shaft (see illustration). Ensure ratchet is set so that it will

tighten counter clockwise on the right hand side, and clockwise on the left hand side. If ten-

sion is present, remove the ratchet and check the left hand side. If spring(s) have tension, the

door will need to be balanced; refer to step, Balancing Door, to do this. If no spring tension is

present, contact a qualiﬁed trained door system technician to replace the spring(s).

IMPORTANT: TO AVOID POSSIBLE INJURY, HAVE A TRAINED DOOR SYSTEMS TECHNICIAN

MAKE ADJUSTMENTS/ REPAIRS TO COUNTERBALANCE LIFT CABLES, SPRING ASSEMBLIES

AND OTHER HARDWARE.

La ausencia de espacio entre el

gatillo del tambor y el tambor para

cable indica activación

La presencia de espacio entre el

gatillo del tambor y el tambor para

cable indica que no hay activación

Gatillo del

trinquete

Vista de abajo

Vista lateral

Gatillo del

tambor Gatillo del

tambor

Tambor

para cable Tambor

para

cable

Envoltura para tambor

(si corresponde)

Llave de

trinquete

Soporte de

extremo

Gatillo

Eje de

enrollamiento

Rueda de trinquete

Perilla del gatillo

en la posición

inferior

Perilla del gatillo

en la posición

superior

Gatillo

Extensión de

trinquete de

3 pulgadas

Llave de vaso de

5/8 de pulgada

Etiqueta de instrucciones de

reajuste del TorqueMaster®Plus

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.

Soporte del operador

de la barra de tracción

Lengüetas del soporte del

operador de la barra de tracción

Pasador de horquilla de 5/16

de pulgada x 1-1/4 pulgadas

Brazo de la puerta

Pasador de

chaveta

Separe el pasador

de chaveta

Pasador de

horquilla

Trolley Arm Conﬁguration

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 opera-

tor brackets. Refer to your alternative drawbar operator bracket insert.

Optional Installation

WARNING

PRIOR TO INSTALLING THE OPERATOR TROLLEY ARM TO THE DOOR,

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

CLOSED POSITION, PLACE LOCKING PLIERS 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

OPERATOR TROLLEY ARM TO THE DOOR REMOVE THE LOCKING PLIERS

AND PLUG THE GARAGE DOOR OPERATOR BACK INTO THE OUTLET.

FIG 1

12” or 15”

FIG 2

Horizontal

track

Level

High arc

Top section

Horizontal

radius

High arc

FIG 4FIG 3

TorqueMaster®

counterbalance

Vertical

center line

From step

Typical 1/2”-1”

above high arc

High arc line

Header

Top section

Low headroom track

Level

Inside Lock

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 ap-

proximately 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.

Inside lock

End cap

1/4”-20 x 11/16”

Self drilling screws

Square hole in

vertical track

Lock

(Second)

section

1/8”

Pull Down Rope

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.

Bottom bracket

Pull rope

No. 6 Screw eye

Pull rope

48” to 50”

From ﬂoor

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 models 9405/9605

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

Outside step plate

2-3/16”

1”

Bottom

section

Hex nut

1/4” - 20 x 5/8”

Carriage bolt

Step plate

base

Step plate

slide Assembled inside step plate

#8 screw

Bottom

Section

Strut

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.

CAUTION

NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.

NOTE: Do not use any window cleaning ﬂuids, scouring compounds, gritty cloths or solvent-

based cleaners of any kind.

To clean polycarbonate windows, see www.Wayne-Dalton.com.

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

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 move-

ments. Do not slam your door or throw your door into the open position, this may cause dam-

age 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.

WARNING

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. 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, a drawbar opera-

tor 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 bracket supplied with the door. To

avoid possible damage to your door, Wayne Dalton recommends reinforcing the top section

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 installa-

tion, 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 material

found not to be structurally sound must be replaced. It may be necessary to uninstall part

or all of the door assembly in order to replace defective material. Refer to the supplemental

instructions “Removing an Existing Door / Preparing the Opening” at www.Wayne-Dalton.

com. Inspect the spring(s), 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, except on bottom corner brackets or on the counterbalance assembly. 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, contact a trained door system technician.

WARNING

GARAGE DOOR SPRINGS, COUNTERBALANCE LIFT CABLES, BRACKETS,

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

MANUFACTURER’S INSTRUCTIONS.

WARNING

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

SCREWS ON THE COUNTERBALANCE (END BEARING BRACKETS, DRUMS

OR SPRING 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 brack-

ets above the door) should be engaged to prevent the door from rapidly descending in case

of spring failure or forceful manual operation.

EXTENSION SPRINGS: A restraining cable or other device should be installed on the exten-

sion 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. Using handles or suitable grip-

ping points, 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, center hinges, steel track rollers, bearings and

torsion springs (torsion spring coil surfaces). 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.

CHECK FOR PRESENCE OF SAFETY LABELS:

Maintenance

The adjacent bottom corner

bracket and all cable

retention features including

milford pins, cotter pins, &

clevis pins are under HIGH

SPRING TENSION.

262484 REV1 01/08/10

WARNING

Repairs and adjustments

must be made by an

experienced door

professional or mechanic,

using proper tools and

instructions.

DO NOT REMOVE, COVER OR

PAINT THIS LABEL.

aDivision of Overhead Door Corp.

The adjacent bottom corner

bracket and all cable

retention features including

milford pins, cotter pins, &

clevis pins are under HIGH

SPRING TENSION.

262484 REV1 01/08/10

WARNING

Repairs and adjustments

must be made by an

experienced door

professional or mechanic,

using proper tools and

instructions.

DO NOT REMOVE, COVER OR

PAINT THIS LABEL.

aDivision of Overhead Door Corp.

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

INSTALLATIONOF THE OPENER MUST BE ACCORDING TO

MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS

MUST BE ADJUSTED PROPERLY.

323917 REV2 01/15/2010

IMPORTANT!

SpringTurns

DoorHeight Spring Turns

(6’- 0”)14

(6’- 3”) 14- 1/2

(6’- 5”)15

(6’- 6”)15

(6’- 8”) 15- 1/2

(6’- 9”) 15- 1/2

(7’- 0”)16

(7’- 3”) 16- 1/2

(7’- 6”)17

(7’- 9”) 17- 1/2

(8’- 0”)18

Numberof Installed Spring Turns

300547 REV2 01/15/2010

DivisionofOverhead Door Corp.

HIGHSPRING TENSION CAN CA USE

SERIOUSINJURY OR DE ATH.

DONOTadjust, repair or remove springs or parts to

whichsprings are connected, such as steel brack-

ets,cables, wood blocks, fasteners or other parts of

thecounterbalance system.

Adjustmentsor repairs must ONLY be made by a

traineddoor systems technician using proper tools

andinstructions.

DONOTremove, cover or paint over this tag. Prod-

uctuser should inspect this tag periodically for

legibilityand should order a replacement tag from

thedoor manufacturer, as needed.

102081 REV2 06/24/2010

SAFETYINSTRUCTIONS

1. Operatedoor ONLY when it is properly

adjustedandfree of obstructions.

2. Ifa door becomes hard to operate,

inoperativeoris damaged, immediately

havenecessaryadjustments and/or repairs

madebya trained door system technician

usingpropertools and instructions.

3. DONOT stand or walk under a moving door,

orpermitanybody to stand or walk under

anelectricallyoperated door.

4. DONOT place ﬁngers or hands into open

sectionjointswhen closing a door. Use lift

handles/grippingpointswhen operating

doormanually.

5. DONOT permit children to operate garage

doorordoor controls.

6. Dueto constant extreme spring tension,

DONOTattempt any adjustment, repair or

alterationtoany part of the door,

especiallytosprings, spring brackets,

bottomcornerbrackets, red colored

fasteners,cablesor supports. To avoid

possiblesevereor fatal injury, have any

suchworkperformed by a trained door

systemtechnicianusing proper tools and

instructions.

7. Onelectrically operated doors, pull down

ropesmustbe removed and locks must be

removedormade inoperative in the open

(unlocked)position.

8. Topsection of door may need to be

reinforcedwhenattaching an electric

opener. Check door and/or opener

manufacturer’s instructions.

9. VISUALLYinspect door and hardware

monthly for worn and/or broken parts.

Check to ensure door operates freely.

10.Te stelectric opener’s safety features

monthly, following opener manufacturer’s

instructions.

11.NEVER hang tools, bicycles, hoses, clothing

or anything else from horizontal tracks.

Track systems are not intended or designed

to support such extra weight.

Placelabel at a readable height on door. DO NOT

remove,cover or paint over this label. Product

usershould inspect this label periodically for

legibilityand should order a replacement label

fromthe door manufacturer as needed.

324100 REV7 09/16/2013

Qualitygarage doors since 1954

WayneDalton

2501S. State Hwy 121 Bus., Suite 200

Lewisville,TX 75067

Forservice, call (800) 827-3667

www.Wayne-Dalton.com

DivisionofOverheadDoor Corp.

Residential warning label

The warning label will either be on

the right or the left end stile.

Drawbar operator

bracket label

Bottom corner bracket warning labels

Torsion spring tag(s)

(one per spring)

TorqueMaster®Plus tag(s)

(one per spring)

Limited Warranty

Models 9100, 9405 and 9605

Wayne Dalton, a division of Overhead Door Corporation (“Seller”) warrants to the original purchaser of the Models 9100, 9405 and 9605 (“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