background image

Bottom of strut

(2) 1/4”-14 x 5/8” 

Self tapping screws

Top fixture roller slide

Top 

section

Insert short stem 

track roller

Attaching Drawbar Operator Bracket

 

12

 

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.

Stacking Top Section

 

13

 

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.

FOR ANGLE MOUNT TRACK:

 Complete the vertical track installation by securing the jamb 

bracket(s) and or tightening the other lag screws. Push the vertical track against the track 

rollers so that the track rollers are touching the deepest part of the curved side of the vertical 

track, as shown. Repeat for other side.

Top 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 or 

wallangle assembly

Top of flag angle or 

Top of wallangle assembly

Attaching Horizontal Tracks

 

14

 

NOTE:

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

Angles, Riveted Vertical Track Assemblies or you may have Angle Mount Vertical Track As-

semblies. 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

IF YOU HAVE ANGLE MOUNT:

 To install horizontal track, place the curved end over the 

top track roller of the top section. Align the bottom of the horizontal track with the top of the 

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

bolts and (2) 1/4” - 20 flange hex nuts.

10

Summary of Contents for 9100

Page 1: ...ance Installation Instructions 11 Optional Installation 17 Door Arm Hookup 17 Trolley Arm Configuration 17 Inside Lock 17 Pull Down Rope 17 Step Plate 17 Maintenance 19 Cleaning Your Garage Door 19 Painting Your Garage Door 19 Maintaining The Finish On Your Garage Door 19 Operation And Maintenance 19 Warranty 21 Wayne Dalton a division of Overhead Door Corporation Models 9100 9405 9605 T o r s i o...

Page 2: ...NGTH 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 i...

Page 3: ...erstrips 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...

Page 4: ...entified by the warning label attached to either the right or left hand end stile The INTERMEDIATE SECTION II can be identified having no labels attached to the section The INTERMEDIATE SECTION III can be identified having no labels attached to the section The INTERMEDIATE SECTION IV can be identified having no labels attached to the section The TOP SECTION can be identified with no pre installed ...

Page 5: ... Track Assembly I6 Right Hand Riveted Vertical Track Assembly J TORSION SPRING ASSEMBLY AS REQUIRED J1 Left Hand and Right Hand Torsion Springs As Required J2 Counterbalance Lift Cables J3 Left Hand End Bearing Bracket As Required J4 Right Hand End Bearing Bracket As Required J5 Left Hand Cable Drum J6 Right Hand Cable Drum J7 Center Bracket As Required J8 Center Bracket Bearing As Required J9 Tor...

Page 6: ... 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 ...

Page 7: ... to the section by placing 2 1 4 14 x 5 8 self tapping screws midway between the end of the door and the center hinge s locations and 1 1 4 14 x 5 8 self tapping screw approximately eight inches from each end FOR THE WINDLOAD OPTION CODE 0356 1 Place the strut over the top rib of the bottom section Center the strut left to right on the section surface Fasten the strut at each end with 2 1 4 14 x 5...

Page 8: ...ing 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 9 NOTE Depending on your door you may have Quick Install Flag Angles Fully ...

Page 9: ...er 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 Cent...

Page 10: ...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 ...

Page 11: ...g screws Top fixture roller slide COUNTERBALANCE INSTALLATION INSTRUCTIONS Attaching End Bearing Brackets 16 NOTE Refer to Package Contents Breakdown of Parts to determine which End Bearing Brackets you have NOTE Prior to fastening end bearing brackets into the door jamb pilot drill using a 3 16 drill bit IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE BUILDING LOOKING OUT NOTE ...

Page 12: ...NTER BRACKET S IF MOUNTING SURFACE IS A 2 X 6 BOARD INSTALLED ON TOP OF MASONRY DRILL A CLEARANCE HOLE IN MASONRY FOR THE 5 16 X 2 1 2 RED HEAD LAG SCREWS 5 16 x 1 5 8 Hex head lag screws RED HEAD Vertical line Mounting surface 17 Minimum Horizontal line Vertical line 2 Center bearing brackets spaced 6 to 7 apart from the center of the door Center of door 12 5 16 x 1 5 8 Hex head lag screw RED HEA...

Page 13: ...ng assembly and slide one end of the torsion keyed shaft through the end bearing bracket Lay the other side of the torsion keyed shaft into the center bracket Repeat the same process for the right hand torsion spring assembly Torsion keyed shaft Center bracket bearing Coupler half Center bearing brackets Left hand end bearing bracket Right hand end bearing bracket Torsion keyed shaft Right wound r...

Page 14: ... Adjust cable tension as needed until right and left cables both respond the same Once the counterbalance cables are set and if applicable tighten the coupler assembly together by tightening the 3 3 8 16 nylon hex nuts to secure the coupler halves together Typicall left hand cable drum Counterbalance lift cable hooked in cable drum Counterbalance lift cable Torsion shaft Torsion keyed shaft Typica...

Page 15: ...prings or parts to which springs are connected such as steel brack ets cables wood blocks fasteners or other parts of the counterbalance system Adjustments or repairs must ONLY be made by a trained door systems technician using proper tools and instructions DO NOT remove cover or paint over this tag Prod uct user should inspect this tag periodically for legibility and should order a replacement ta...

Page 16: ...or can cause garage door operator problems To adjust spring tension fully close door Apply locking pliers to track above third track roller Place locking pliers on torsion shaft as shown in Step Attaching Counterbalance Lift Cables Insert a winding rod into the winding cone Push upward on the winding rod slightly while carefully loosening the set screws in the winding cone IMPORTANT BE PREPARED TO...

Page 17: ...y NOTE Depending on your door configuration you could have an alternative drawbar opera tor brackets Refer to your alternative drawbar operator bracket insert 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 T...

Page 18: ...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 ...

Page 19: ...on 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 av...

Page 20: ...erate door ONLY when it is properly adjusted and free of obstructions 2 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 3 DO NOT stand or walk under a moving door or permit anybody to stand or walk under an electrically operated door 4 DO NOT place fingers ...

Page 21: ...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 ...

Page 22: ...ervice representative They will be happy to handle any questions that you may have Thank you for your purchase PLEASE DO NOT RETURN THIS PRODUCT TO THE STORE After installation is complete leave this Installation Instructions And Owner s Manual with the homeowner or fasten it near garage door for easy reference ...

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