Wayne-Dalton 9600 Installation Instructions And Owner'S Manual Download

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9100, 9400 and 9600 Series

Part No. 328740

REV1 08/03/2009

TorqueMaster

Plus - Single and Double Spring

Installation Instructions and Owner’s Manual

Portland Source Plant

Wayne-Dalton Corp.

P.O. Box 67

Mt. Hope, OH 44660

www.wayne-dalton.com

IMPORTANT NOTICE!

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.

Summary of Contents for 9600

Page 1: ...nstructions and Owner s Manual Portland Source Plant Wayne Dalton Corp P O Box 67 Mt Hope OH 44660 www wayne dalton com IMPORTANT NOTICE Read these instructions carefully before attempting installatio...

Page 2: ...ring tension DO NOT attempt any adjustment repair or alteration to any part of the door especially to springs spring brackets bottom corner brackets red colored fasteners cables or supports To avoid p...

Page 3: ...and Cable Drum indicat es engage ment Cable Drum Ratche t Pawl ENGAG ED SIDE VIEW No space betwee n Ratche t Pawl and Cable Drum ENGAG ED UNDER NEATH VIEW Space betwee n Ratche t Pawl and Cable Drum...

Page 4: ...y the bottom bracket warning labels on each end stile This section is always the 1st section from the bottom of the door The lock section can be identified by a 2 end hinge This section is always the...

Page 5: ...re level vice clamps pencil 3 16 7 16 1 8 drill bits flat tip screwdriver 3 extension Counterbalance spring tension must always be released before any attempt is made to start removing an existing doo...

Page 6: ...t 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 Plus counterbalance systems For low hea...

Page 7: ...I Jamb Brackets 3rd SET HOLES 2nd SET HOLES twistlock tab left side shown right side shown Tape Measure Hacksaw Power Drill 5 16 Drill Bit Vertical track must be cut to the proper length prior to ins...

Page 8: ...ngle to Vertical Track None Hand tighten the flagangle to the vertical track using 2 1 4 20 x 5 8 carriage bolts and 2 1 4 20 flange hex nuts Repeat for opposite side The flange nuts will be tightened...

Page 9: ...il the counterbalance cables and make sure you place the right hand cable loop on the right hand milford pin and place the left hand cable loop on the left hand milford pin Insert a roller into bottom...

Page 10: ...rs of the bottom section Make sure the counterbalance cable is located between the rollers and the door jamb NOTE Vertical track needs held 1 2 off ground Drill 3 16 pilot holes for the lag screws Loo...

Page 11: ...section with 3 1 4 14 x 5 8 self tapping screws Attach center hinges first then attach the end hinges last Now secure the end hinge leafs to the section with 2 1 4 14 x 5 8 self tapping screws and fas...

Page 12: ...ts may be pre assembled in some cases To install the L shaped top brackets align the top holes in the top bracket base with a the second set of holes in the endstile for 14 radius track b the first se...

Page 13: ...NOTE Model 9400 9600 glazed top doors 13 0 wide or greater will be supplied with a 3 asymmetrical U bar for the top section Place the 3 asymmetrical U bar over the top rib Fasten each end of the U ba...

Page 14: ...tioned on the top section as illustrated Install 2 12 x 1 2 phillips head screws on the top flange of the operator bracket U BAR INSTALLED If a U Bar is installed on the top section clamp the bottom f...

Page 15: ...end hinges last Refer to Step 6 When installing a door with Torquemaster Plus counterbalance system vertical track alignment is critical Position flagangle between 1 11 16 43 mm to 1 3 4 44 mm from t...

Page 16: ...M OVERHEAD POSI TION CAUSING SEVERE OR FATAL INJURY Level the horizontal track assembly and bolt the horizontal angle to the slot in the flagangle using 1 3 8 16 x 3 4 hex head bolt and 1 3 8 16 hex n...

Page 17: ...installed you can now adjust the top brackets Vertically align the top section of the door with the lower sections Once aligned position the top bracket slide out against the horizontal track Maintai...

Page 18: ...ENTER BRACKET ASSEMBLY TorqueMaster Spring Tube TorqueMaster Spring Tube CENTER BRACKET BUSHING None NOTE If you are installing the opener with your garage door skip this step and go to your idrive In...

Page 19: ...RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE GARAGE LOOKING OUT Drum wraps are identified as right and left Slide the left hand drum wrap over the left side of the TorqueMaster spring tube...

Page 20: ...pring applications Insert the loose winding shaft into the left hand cable drum prior to sliding the cable drum over the TorqueMaster spring tube assembly NOTE On single spring applications take care...

Page 21: ...t is und er EX TR EM E SP RIN G TE NS ION To avo id pos sib le sev ere or fata l inju ry DO NO T rem ove fas ten ers from ratche t bra cke t unt il spr ing s are full y wn wo und To saf ely unw ind sp...

Page 22: ...x 2 hex head lag screws NOTE If you are not installing the idrive opener on your garage door you must install the center bracket bushing assembly follow these instructions To locate the center bracke...

Page 23: ...ton com Tools Needed INSTALLATION Place vice clamps onto both vertical tracks just above the third roller This is to prevent the garage door from raising while winding counterbalance springs Failure t...

Page 24: ...e drum Snug the set screw and then tighten an additional 1 1 2 turns Left side will be adjusted in Step 23 IMPORTANT ENSURE THE CABLE IS ALIGNED AND SEATED IN THE FIRST GROOVE OF THE CABLE DRUM PRIOR...

Page 25: ...of the left hand side but need cable tension adjustments IMPORTANT Counterbalance cable tension must be equal on both sides prior to fully winding springs See the Spring Turn chart for the required n...

Page 26: ...until horizontal tracks are secured at the rear as outlined in step 24 raising door further can result in door falling and cause severe or fatal injury Spring Turns Door Height Spring Turns 6 0 14 6...

Page 27: ...tal track parallel and within 3 4 maximum of door edge otherwise door could fall resulting in severe injury or death IMPORTANT DO NOT SUPPORT THE WEIGHT OF THE DOOR ON ANY PART OF THE HORIZONTAL TRACK...

Page 28: ...the spring tension Release the pawl to allow it to engage with the ratchet wheel IMPORTANT BE PREPARED TO HOLD THE FULL TENSION OF THE SPRING IMPORTANT do not add or remove more than 1 spring turns 1...

Page 29: ...OTE Proceed with TorqueMaster Plus Reset Instructions if it is absolutely necessary to open the garage door contact your nearest qualified Wayne Dalton repair center for repairs Resetting the anti dro...

Page 30: ...side and clockwise on the left hand side if applicable If tension is present remove the ratchet and check the left hand side if applicable If spring s have tension proceed to Balancing Door if no spr...

Page 31: ...e Place the ratchet with 5 8 socket onto the winding shaft pull down to add 3 10 of a turn Watch as three teeth of the ratchet wheel pass over the ratchet pawl creating three clicks To Remove Spring T...

Page 32: ...e square hole in the vertical track The side lock should be spaced in approximately 1 8 from the section edge IMPORTANT side locks must be removed or made inoperative in the unlocked position if an op...

Page 33: ...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...

Page 34: ...der Using the operator hook up charts refer to referenced illustrations in FIG 2 4 through FIG 2 5 for correct arm hook up from trolley to operator bracket NOTE Refer to your operator manual for speci...

Page 35: ...o header Using the operator hook up charts refer to referenced illustrations in FIG 3 3 through FIG 3 4 for correct arm hook up from trolley to operator bracket NOTE Refer to your operator manual for...

Page 36: ...e high arc of top section of the door 2 Mount operator to ceiling so that 1 to 1 1 2 25 38 mm clearance is maintained between trolley rail and top section when door is fully open trolley rail will slo...

Page 37: ...ill scratch the acrylic glazing Dry glazing with a clean damp chamois NOTE DO NOT USE any window cleaning fluids scouring compounds gritty cloths or solvent based cleaners of any kind Surface Preparat...

Page 38: ...Continued NOTES 1 Repainting of finish painted steel doors cannot be warranted as this condition is totally beyond the door manufacturer s control 2 Consult a professional coatings contractor if in do...

Page 39: ...ess Manufacturer s preparation and painting instructions are followed explicitly This Limited Warranty will be voided if any holes are drilled into the door other than those specified by the Manufactu...

Page 40: ...6 7 036 548 7 059 380 7 121 317 7 128 123 7 134 471 7 134 472 7 219 392 7 254 868 Canadian 2 384 936 2 477 445 2 495 175 2 507 590 2 530 701 2 530 74 2 2 532 824 Other US and Foreign Patents pending C...

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