9900 Thermowayne™ 9600 Thermogard® 9200 Foamcore™
Torsion Spring
Installation Instructions and Owners Manual
NYLON CENTER
BUSHING
CENTER BEARING
BRACKET
RIGHT HAND WOUND
TORSION SPRING (RED)
LEFT HAND WOUND
TORSION SPRING (BLACK)
END BEARING
BRACKET
END BEARING
BRACKET
TORSION TUBE
LEFT HAND CABLE
DRUM
RIGHT HAND
CABLE DRUM
REAR SUPPORT ASSEMBLY
(NOT SUPPLIED)
HORIZONTAL
ANGLE
Parts List
TOP BRACKET BASE
# 158044
# 158046
# 154489
1 PAIR
TOP BRACKET
TOP BRACKET SLIDE
ROLLER
VERTICAL TRACK
HORIZONTAL
TRACK
FLAGANGLE
TL-1 JAMB BRACKET
TL-2 JAMB BRACKET
TL-3 JAMB BRACKET
# 261965
# 261966
# 261967
1 PAIR
# 240380
# 240381
# 240382
# 240383
# 292536
# 292539
# 292538
AS REQUIRED
AS REQUIRED
1 PAIR
COUNTERBALANCE
CABLE
HORIZONTAL TRACK
12” FLAGANGLE (LEFT)
12” FLAGANGLE (RIGHT)
15” FLAGANGLE (LEFT)
15” FLAGANGLE (RIGHT)
22-1/16” HORIZ. ANGLE
80” HORIZ. ANGLE (RIGHT)
80” HORIZ. ANGLE (LEFT)
TORSION SPRING (RED)
TORSION SPRING (BLACK)
COUNTERBALANCE CABLES
CABLE DRUM (RIGHT)
CABLE DRUM (LEFT)
CENTER HINGE
#3 END HINGE
#2 END HINGE
VERTICAL
TRACK
ROLLER
TL-2 JAMB
BRACKET
TL-1 JAMB
BRACKET
# 284653
# 284654
# 279134
END BEARING BRACKET (LEFT)
END BEARING BRACKET (RIGHT) # 103415
#1 END HINGE
CENTER BEARING BRACKET
NYLON CENTER BUSHING
# 6 SCREW EYE
# 100298
# 103336
# 100362
# 274884
BOTTOM BRACKET
ASTRAGAL
INSIDE STEP PLATE
PULL ROPE &
SCREW EYE
60” PULL ROPE
NOTE: DEPENDING ON YOUR DOOR MODEL, SOME PARTS
LISTED MAY NOT BE SUPPLIED IF NOT NECESSARY.
OUTSIDE STEP PLATE
© Copyright 2002 Wayne-Dalton Corp.
Rev.2 02/02
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PART NO. 248438
IMPORTANT!
JAMBS, HEADER, AND SPRING PAD MUST BE
SECURELY ATTACHED TO FRAMING MEMBERS.
CHECK BEFORE INSTALLING NEW DOOR.
IMPORTANT!
12 - 17
REAR SUPPORT ASSEMBLIES MUST BE
SECURELY ATTACHED TO CEILING
FRAMING MEMBERS ADEQUATE TO
HOLD THE WEIGHT OF THE DOOR.
11
2
NOTE:
10
18
DOORS WITH OPERATORS,
SEE STEP 21
9
IMPORTANT!
8
DOOR OPENING PREPARATION IS CRITICAL FOR PROPER
DOOR INSTALLATION. CHECK THE OPENING TOP, AND
SIDES TO ENSURE IT IS LEVEL AND SQUARE. CORRECT IF
NECESSARY BEFORE INSTALLING NEW DOOR.
1
IMPORTANT!
IF INSTALLING A REPLACEMENT DOOR, CHECK THE OPENING
SIZE AND NEW DOOR SIZE, MAKING SURE THEY MATCH
BEFORE REMOVING EXISTING DOOR.
6
NOTE:
SINGLE WIDE DOOR SHOWN IN ILLUSTRATION (SOME
LIGHTER WEIGHT DOORS ARE SUPPLIED WITH ONE (1)
TORSION SPRING)
NOTE: SIDE LOCK INSTALLA-
TION OPTIONAL
5
7
SIDE LOCK
INSTALLATION
INSTALLATION IS ON SECOND
SECTION OF DOOR. SECURE
THE LOCK TO THE SECTION
WITH (4) 1/4-20 X 5/8” SELF
DRILLING SCREWS. SQUARE
LOCK ASSEMBLY WITH DOOR
SECTION AND HOLE IN
3
4
IMPORTANT! IT IS RECOM-
MENDED THAT SIDE LOCKS BE
REMOVED IF AN OPERATOR IS
NOTE:
STEP PLATE
OPTIONAL
VERTICAL TRACK. THE SIDE
LOCK SHOULD BE SPACED
INSTALLED ON THE DOOR.
20
19
APPOX. 1/8” FROM THE
SECTION EDGE.
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TOP BRACKET
SLIDE
START HERE
COUNTERBALANCE
CABLE FOR LEFT HAND
DRUM
TOP SECTION
RIB
MILFORD
PIN
ROLLER
IMPORTANT! READ IMPORTANT SAFETY NOTICES AND REFER TO
INSERT SHEET INSTRUCTIONS TITLED “REMOVING THE OLD DOOR/
PREPARING THE OPENING”. IF THE INSERT SHEET INSTRUCTIONS
ARE NOT INCLUDED, CONTACT WAYNE-DALTON CORP. FOR A FREE
COPY.
(2) 1/4-20
CARRIAGE BOLTS
AND NUTS
CABLE LOOP
1ST SET OF HOLES ON
9900 THERMOWAYNE™
TOP BRACKET
2ND SET OF HOLES ON
9600 THERMOGARD®
BOTTOM
SECTION
If removing an existing door, carefully follow the directions given on the
insert sheet instruction in the portion titled “Removing the Old Door”.
(4) 1/4-20 x 5/8”
SELF TAPPING
SCREWS
3RD SET OF HOLES ON
9200 FOAMCORE™
LEFT HAND
BOTTOM
BRACKET
8
WARNING!
REMOVALOFAN EXISTINGDOOR CAN BE DANGEROUS. FOLLOW
INSERT SHEET INSTRUCTIONS CAREFULLY, OTHERWISE SERIOUS
INJURYOR DEATH COULD RESULT.
ROLLER
4
To install the L-shaped top brackets, align the top holes in the top bracket with
the first set of holes in the endcap for 9900 Thermowayne™ doors, second set
for 9600 Thermogard® doors and third set on all 9200 Foamcore™ doors.
Fasten using (4) 1/4-20 x 5/8” tapping screws. Secure the top bracket slide to the
bracket using (2) 1/4-20 carriage bolts and nuts. Insert rollers.
Uncoil the counterbalance cables and slip the loops at the ends of the cables
over the milford pins on the bottom brackets of the bottom section. Place a
roller in each of the bottom brackets, as well as the end hinges at the top of the
section.
Begin the installation of the door by checking the opening. It must be the same
size as the door. Vertical jambs must be plumb and the header level. Side
clearance, from edge of door to wall, must be minimum of 3-1/2” (89 mm) on
each side. For proper opening preparation refer to the portion of the insert
sheet instructions titled “Preparing the Opening”.
IMPORTANT! Right and left hand is always determined from inside the
building looking out.
1/4-20 x 5/8” SELF
3” U-BAR
FLAGANGLE
DRILLING SCREW
9
ALIGN TAB INTO
TOP HOLE IN
TRACK AND
FOAMCORE™ II
TWIST UP UNTIL
PARALLEL WITH
TRACK
TOP SECTION
(MODEL 9200)
TOP RIB
TOP SECTION
VINYL WEATHER STRIPPING
TEMPORARILY NAILED TO JAMBS
(REFER TO INSERT SHEET ON
PREPARING THE OPENING.)
VERTICAL
TRACK
9200 Foamcore™ doors over 13’wide require a 3” U-Bar. Center the U-Bar over
the top rib on the top section and secure it to the section using (6)
1/4-20 x 5/8” self drilling screws. Place top section in the door opening and
secure it temporarily by driving a nail into the header near the center of the door
and bending it over the section. Now flip, hold and fasten the hinges.
1
Assemble the Wayne-Dalton Twistlock™, Slidelock™ track system. First,
put the Twistlock tabs on the flagangle into the Twistlock holes on the vertical
track. Give the flagangle 1/4 turn to lock in place.
NOTE: Twistlock™ track components - U.S. patent no. 5,408,724 and
5,568,672.
LEVEL
(2) 5/16” x 1-5/8”
LAG SCREW
80” HORIZONTAL ANGLE
BOTTOM ASTRAGAL
TOP SECTION
2
5
NOTE: CABLE SHOULD
BE BETWEEN TRACK
AND DOOR AND
BEHIND ROLLERS
ALIGN TABS INTO SLOTS,
PUSH TOGETHER AND TAP
FORWARD WITH HAMMER
FLAGANGLE
Before installing the bottom section, measure and cut vinyl jamb weather-
stripping for entire garage door opening. Temporarily nail the weather-strip-
ping to the door jambs and header. This will help hold the bottom door section
in place. Refer to the insert sheet on preparing the opening.
10
22-1/2”
HORIZONTAL
ANGLE
Position the flagangle 1-11/16” (43 mm) from the edge of the door. Tighten the
first lag screw then secure flagangle to the jamb with (2) 5/16” x 1-5/8” lag
screws.
Now comes the single most important step in installing the Wayne-
Dalton garage door system. Center the bottom section in the door open-
ing. Level it using wooden shims under the bottom astragal as needed. Once
the bottom section is level, all the other components will automatically align.
Hold the section in the opening while attaching vertical tracks. Align the
bottom of the vertical tracks with the bottom of the section. If you leveled the
bottom section with shims on one side, then the vertical track on that side
must be raised off the floor an amount that’s equal to the thickness of the
shim(s).
HORIZONTAL
TRACK
IMPORTANT! Ensure that flagangles are parallel with the door sections.
Align the Slidelock™ tabs on the applicable horizontal angle with key slots in
the horizontal track. Push the parts together. Using a hammer, tap the hori-
zontal angle towards the curved end of the track until the hole in track and angle
are aligned. Set tracks aside.
IMPORTANT! The dimension between the flagangles must be exactly door-
width plus 3-3/8” (86 mm) for smooth, safe door operation.
Now complete the vertical track installation on both sides by securing center
jamb bracket and tightening other lag screws.
NOTE: For larger size doors, a full length horizontal angle is already spot
welded to the horizontal track.
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ALIGN IN PROPER
HOLE AND TWIST TO
BACK OF TRACK
COUNTERBALANCE
CABLE
3/8-16 x 3/4”
TRUSS HEAD
BOLT & NUT
ROUND
NOTCH
3
CABLE DRUM
FLAGANGLE
HORIZONTAL
ANGLE
JAMB
BRACKET
5/16” x 1-5/8”
LAG SCREW
VERTICAL
TRACK
BOTTOM JAMB
BRACKET
FLAGANGLE
CENTER JAMB
BRACKET
11
BOTTOM
SECTION
To install horizontal track, place the curved end over the top roller. Align the
key slot in the track with the quick install tabs on the flagangle. With a
pivoting motion, push the curved portion of the horizontal track downward to
lock into place, while raising the rear of the horizontal to align the horizontal
angle with the flagangle. Bolt the horizontal angle to the flagangle using (1)
3/8-16 x 3/4” truss head bolt and nut. Repeat for other side. With track
installed you can adjust the top brackets. Vertically align the top section with
the lower sections. Once aligned, move adjustable slide out to force top roller
against horizontal track. Tighten 1/4-20 nuts to secure slide to top bracket.
Repeat for other side. Remove nail that was temporarily holding top section in
place.
VERTICAL TRACK
5/16” x 1-5/8”
LAG SCREW
6
Measure the length of the vertical tracks. Using the table, determine the
placement of the jamb brackets for your door height. Align the Twistlock™
wings on each jamb bracket with the correct butterfly hole in the track and turn
the jamb bracket perpendicular to the track so the mounting flange is toward
the back leg of the track.
Position the first vertical track over the rollers of the bottom section. Make
sure the counterbalance cable is located between the rollers and the door jamb.
Align the marks on the vertical track from step 3 with the vertical track line
stamp on the endcap and loosely fasten bottom jamb bracket and flagangle with
(1) 5/16” x 1-5/8” lag screw each, but do not secure the center jamb bracket yet.
Install the other vertical track the same way. Run the counterbalance cables up
between vertical track and edge of door section. Hang the cables over the tops
of the the flagangles in round notch.
IMPORTANT! Failure to remove nail before attempting to raise door could
cause permanent damage to top section. DO NOT ATTEIMPT TO RAISE
DOOR AT THIS POINT.
IMPORTANT! The tops of the vertical tracks must be level from side to side.
WARNING!
(2) 1/4-20 x 5/8” SELF
VERTICAL
DO NOT RAISE DOOR UNTILHORIZONTALTRACKSARE SECURED
AT REARAS OUTLINED IN STEP#18, OR DOOR COULD FALLFROM
OVERHEAD POSITION CAUSINGSEVERE INJURY OR DEATH.
TAPPING SCREWS
(3) 1/4-20 x 5/8” SELF
TAPPING SCREWS
TRACK
END HINGE #1
ON BOTTOM
SECTION
DOOR HEIGHT
TL-1
TL-2
TL-3
N/A
JAMB
LEFT HAND END
BEARING BRACKET
ALIGN
EDGE OF
SECTIONS
6'0"
64" TRACK
(1626 mm)
5/16” X 1-5/8”
LAG SCREW
BOTTOM
BOTTOM
CENTER
HINGE
NOTE:
TL-3
HOLES
6'5"
69" TRACK
(1753 mm)
IDENTIFY LOCK
SECTION BY THE
#2 STAMP ON
MIDDLE
MIDDLE
BOTTOM
MIDDLE
BOTTOM
MIDDLE
MIDDLE
BOTTOM
BOTTOM
BOTTOM
BOTTOM
BOTTOM
MIDDLE
MIDDLE
N/A
N/A
UPPER SLOTS
USED ON 15”
RADIUS TRACK
(2) 3/8-16 x 3/4”
TRUSS HEAD
BOLT
6'6"
70" TRACK
(1778 mm)
7
THE END HINGE
FLAGANGLE
6'8"
72" TRACK
(1829 mm)
Make sure top leaves of all hinges on the bottom section are folded down.
Insert rollers into the end hinges of the second section, also called the lock
section. With assistance lift section and place rollers over the tops of the
vertical tracks. Install by guiding rollers into the vertical track on both sides
and gently lowering this section onto the bottom section. Keeping the ends of
the sections aligned, install remaining section(s), except top section, in same
manner. Fasten all hinges to connect the sections by flipping up the hinge leaf,
holding it firmly against section and driving in the supplied 1/4-20 x 5/8” self
tapping screws.
NOTE: Two (2) 1/4-20 x 5/8” self tapping screws are used for each end hinge
leaf, while three (3) screws are used for each center hinge. The screw place-
ment is staggered in the end hinges, with the screw nearest the edge of the door
going into the lower hole and the inside screw going into the upper hole.
HORIZONTAL
ANGLE
N/A
(2) 3/8 - 16
HEX NUTS
7'0"
76" TRACK
(1930 mm)
TL-2
HOLES
N/A
LOWER SLOTS USED
ON 12” RAD. TRACK
12
7'3"
79" TRACK
(2007 mm)
BOTTOM
MIDDLE
MIDDLE
7'6"
82" TRACK
(2083 mm)
Attach the left hand end bearing bracket to the horizontal angle with
(2) 3/8-16 x 3/4” truss head bolts and nuts. Once the bracket is secured, fasten
the bracket to the jamb with (1) 5/16 x 1-5/8” lag screw. Repeat for the right
hand side.
7'9"
85" TRACK
(2159 mm)
TL-1
HOLES
NOTE: End bearing brackets are to be attached using the lower slots on 12”
radius track and using the upper slots on 15” radius track.
8'0"
(4 SECTIONS)
(5 SECTIONS)
88" TRACK
(2235 mm)
MIDDLE
TOP
MIDDLE
TOP
MIDDLE
MIDDLE
IMPORTANT! Once fastener is snug against hinge leaf, tighten an additional
1/4 to 1/2 turn to achieve maximum design holding power.
IMPORTANT! Right and left hand are always determined from inside the build-
ing looking out.
NOTE: Jamb brackets are stamped for identification.
NOTE: To install lock, see lock instructions included in the lock assembly bag.
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CENTER BEARING BRACKET
(2) 3/8-16 x 1-1/4” BOLT
CODED WINDING CONE:
RIGHT HAND WOUND
(MOUNTS ON LEFT SIDE)
CENTER BEARING BRACKET
HORIZONTAL PENCIL LINE
13
15
SPRING WITH RED COLOR
5/16” x 1-5/8”
LAG SCREW
SPRING WARNING
LABEL
WINDING BARS
(2 REQUIRED)
TORSION
TUBE
WINDING CONE
SPRING
(2) 3/8-16 NUT
WARNING
LABEL
NYLON CENTER
BUSHING
STATIONARY
SPRING CONE
VERTICAL PENCIL LINE
(CENTERLINE OF THE DOOR)
TAMPER-PROOF LAG SCREW
5/16” x 2” OR 5/16 x 1-5/8” -
SPRING PAD OVER MASONRY
Slide the nylon center bushing into the end of (1) stationary spring cone and
align the cone(s) with the holes in the center bearing bracket. Secure the
spring(s) to the center bearing bracket with (2) 3/8-16 x 1-1/4” bolts and nuts.
Locate the center of the door and mark a vertical pencil line on the spring pad.
Then measure the distance from the center of the mounting hole in the end
bearing bracket to the top of the door. Using that same distance, mark a horizon-
tal line on the spring pad, measuring up from the top of the door. Position the
center bearing bracket along the vertical pencil line on the spring pad as shown.
In addition, position the center bearing bracket halfway over the horizontal
pencil line. This will level the torsion tube through the end bearing brackets when
installed. Attach the center bearing bracket to the spring pad using (2) 5/16” x 1-
5/8” lag screws and (1) 5/16” x 2” tamper-proof lag screw.
SET SCREWS
(TORQUE TO 14-15 ft-lbs.)
17
IMPORTANT! Springs under tension can be dangerous. Spring warning tag
must be attached to center bearing bracket in obvious sight. If this tag is
missing, contact Wayne-Dalton Corp. for free replacements.
Position a ladder slightly to the side of spring so that the winding cone is easily
accessible, yet your body is not in the path of the winding bars. Check the
tag(s) attached to the spring(s) for the number of required spring turns.
Clamp locking pliers onto both vertical tracks just above the third roller. This
is to prevent door from raising while winding the spring(s).
6’0” Door Height
6’5” Door Height
6’6” Door Height
6’8” Door Height
7’0” Door Height
7’3” Door Height
7’6” Door Height
7’9” Door Height
8’0” Door Height
=
=
=
=
=
=
=
=
=
Approx. 6-3/4 Turns
Approx. 7 Turns
Approx. 7-1/4 Turns
Approx. 7-1/4 Turns
Approx. 7-1/2 Turns
Approx. 8 Turns
Approx. 8 Turns
Approx. 8-1/4 Turns
Approx. 8-1/2 Turns
IMPORTANT! Use the 5/16” x 1-5/8” tamper-proof lag screw ONLY if spring
pad is mounted over masonry.
WARNING!
FAILURE TO CLAMP TRACK CAN ALLOW DOOR TO RAISE AND
CAUSE SEVERE INJURY OR DEATH.
IMPORTANT! Tamper-proof lag screw MUST be attached through the bottom
hole of the center bearing bracket.
RIGHT CABLE
DRUM (BLACK)
NYLON CENTER
BUSHING
COUNTERBALANCE
RED CABLE DRUM
CABLE
LEFT HAND SIDE
WINDING
Inserting winding bars into holes of winding cone, one after the other, rotate
winding cone upward toward ceiling 1/4 turn at a time until correct number of
turns for your door height is achieved. As the last 1/4 turn is achieved, insert
winding bar in the bottom hole of the winding cone and gradually let tension
OFF the spring, allowing the lower bar to rest against the door and support all
of the spring tension. Stretch the spring 1/4” towards the edge of the door to
create clearance between the spring coils, allowing for smooth operation.
Tighten the set screws on the winding cone to 14 -15 ft.-lbs. of torque. Care-
fully push the upper bar toward the ceiling just enough to free the lower bar,
then SLOWLY remove the upper bar. If required, repeat for the other side.
CONE
TORSION
LEFT HAND WOUND
BLACK WINDING CONE
RIGHT HAND SIDE
TUBE
90° BEND
RIGHT HAND WOUND
RED WINDING CONE
LEFT HAND SIDE
14
LOOSE CABLE
SET SCREW
CRIMPED CABLE
BUTTON
BUTTON
16
Facing the inside of the door, lay the torsion tube on the floor. Lay the black
color coded winding cone with spring and cable drum on the floor at the right end
of the tube. Then lay the red color coded winding cone with spring and cable
drum on the floor at the left end of the tube.
NOTE: Right and left hand is always determined from inside the building looking
out.
NOTE: Some lighter weight doors are provided with only (1) torsion spring.
Identify the spring(s) provided as either right hand wound (red winding cone),
which goes on the LEFT HAND SIDE or left hand wound (black winding cone),
which goes on the RIGHT HAND SIDE.
NOTE: The set screws used on all Torsion Counterbalance cable drums and
winding cones are now painted red. DO NOT identify right and left hand side by
the set screws.
Thread the counterbalance cables behind the rollers and around the back side of
the cable drums. Before hooking the counterbalance cables into the cable drums,
slide the loose cable buttons against the crimped buttons and with a pair of pliers,
bend a 90 degree angle in the counterbalance cable.
IMPORTANT! Pushing the upper bar too far will cause the counterbalance
cables to fall off the cable drums.
Hold the door down to prevent it from rising unexpectedly, in the event the
spring(s) were overwound, and carefully remove the locking pliers from the
vertical tracks. Raise the door until the top section and half of the next section
are in a horizontal position. Do not raise door any further since rear of hori-
zontal track is not yet supported.
Hook the counterbalance cables into the cable drums. Slide the left hand cable
drum against the left hand end bearing bracket and tighten the set screws in the
cable drum. Rotate the left hand cable drum until the counterbalance cable is
taut. CABLE ENDS MUST WRAP DRUM 1/2 TO 3/4 TURN. Clamp locking
pliers to the torsion tube and brace it against the jamb to hold the counterbalance
cable taut.
WARNING!
RAISING DOOR FURTHER CAN RESULT IN DOOR FALLING AND
CAUSE SEVERE INJURY OR DEATH.
Slide the right hand cable drum against the right hand end bearing bracket and
rotate the cable drum until the counterbalance cable is taut. Tighten the set
screws in the cable drum.
Slide the nylon center bushing onto the torsion tube followed by the spring(s) and
cable drums. The nylon center bushing, spring(s), and cable drums must be
positioned as shown in the illustrations. With assistance, pick up the torsion
tube assembly and slide the other end the of tube through one end bearing
bracket. Lay the torsion tube into the center bearing bracket and slide the loose
end of the tube into the opposite end bearing bracket. Position the torsion tube
so that equal amounts of the tube extend from each end bearing bracket.
Now clamp a pair of locking pliers to the vertical tracks just above the second
roller on one side, and just below the second roller on the other side. This will
prevent the door from raising or lowering while installing the rear support.
IMPORTANT! Tighten set screws one (1) full turn after making contact with
the torsion tube. Counterbalance cable tension MUST be equal for both sides.
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PERFORATED ANGLE
(NOT SUPPLIED)
9900 Thermowayne™ 9600 Thermogard®
9200 Foamcore™
5/16” x 2”
LAG SCREWS
(NOT SUPPLIED)
18
5/16” x 1-1/4”
BOLT AND NUT
(NOT SUPPLIED)
Wayne-Dalton Corp.
P.O. Box 67, Mt. Hope, Ohio
44660
IMPORTANT! ANGLE MUST
BE ATTACHED TO FRAMING
MEMBER ADEQUATE TO
SUPPORT DOOR WEIGHT
WITH 5/16” x 2” LAG BOLTS
LIFETIME LIMITED WARRANTY
HORIZONTAL TRACK
The Manufacturer warrants the 9900 THERMOWAYNE, 9600 THERMOGARD and 9200 FOAMCORE insulated garage door for as long as you
own the door from the time of installation against structural failure (rendering the door inoperable) of the door sections due to separation/ degradation
of foam insulation. Other conditions and exceptions as contained herein apply.
5/16” x 1-1/4”
BOLT AND NUT
(NOT SUPPLIED)
EXTEND BOLT
THROUGH TRACK
The Manufacturer warrants the steel skin of the9900 THERMOWAYNE, 9600 THERMOGARD and 9200 FOAMCORE insulated garage door for as
long as you own the door from the time of installation against deterioration such as cracking or splitting due to rust-through. Other conditions and
exceptions contained herein apply.
Using perforated angle, fabricate rear support for horizontal tracks as shown.
Using lag screws, make sure that support is fastened into ceiling joist, or ad-
equate framing members to hold the weight of the door. Keeping the horizontal
track parallel to the edge of the door sections, raise the horizontal track to a
level position and bolt it to the rear support structure. Track must be secured
and braced to prevent movement. The bolt should extend into the track to act
as a roller stop. Repeat for other side. Remove locking pliers and close door.
The Manufacturer warrants the garage door hardware and track, excluding springs, for as long as you own the door against defects in workmanship or
material from time of installation.
After a period of TWENTY YEARS from time of installation, replacement of LIFETIME LIMITED WARRANTY materials are prorated at 50 percent
of Manufacturer’s published pricing at time of claim.
This warranty extends only to the original homeowner, providing the door is installed in his/her place of primary residence. It is not transferable. The
warranty applies to residential property only and is not valid on commercial or rental property.
WARNING!
The Manufacturer warrants that any parts of the door not covered by the above limited warranty will be free from defects in workmanship and material
for ONE YEAR from the time of installation.
KEEP HORIZONTAL TRACK PARALLELAND WITHIN 3/4” (19 mm)
OF DOOR EDGE, OTHERWISE DOOR COULD FALL, RESULTINGIN
SERIOUS INJURY OR DEATH.
The Manufacturer shall, upon notification, correct any nonconformity at its option, by repairing, replacing, or refunding original purchase price of any
defective part(s). This warranty covers material only and excludes all other charges incurred.
NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THE FOREGOING WARRANTIES IN ANY WAY OR
GRANT ANY OTHER WARRANTY ON BEHALF OF MANUFACTURER.
Permanently attach the vinyl weather stripping to both door jambs and the header.
Now, lift the door and check it’s balance. Unwind spring(s) if door lifts by itself
or if it is hard to pull down. Wind spring(s) if door is difficult to lift or too easy to
pull down.
The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of installation, improper storage, unautho-
rized service, alteration of products, neglect or abuse, or attempt to use the products for other than the customary usage or for their intended purposes.
The 9900 THERMOWAYNE, 9600 THERMOGARD and 9200 FOAMCORE warranty becomes null and void if the door is punctured with any hole
or if a hole is drilled into the door sections other than those specified in the notes of installation. This warranty does not cover the product due to
circumstances such as normal wear, damage from corrosive fumes or substances, fire, condensation, vandalism, acts of God, or other causes beyond
Manufacturer’s control, nor replacement or repair labor.
To adjust spring tension, fully close door. Apply locking pliers to track above
third roller. Insert a winding bar into the winding cone. Push upward on the
winding bar while carefully loosening the set screws in the winding cone. BE
PREPAREDTO SUPPORTTHE FULLFORCE OFTHE TORSION SPRING
ONCE THE SET SCREWS ARE LOOSE.
THIS WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS WARRANTY ACT. NO WARRANTIES,
EXPRESSED OR IMPLIED, (INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICU-
LAR PURPOSE), SHALL EXTEND BEYOND THE APPLICABLE TIME PERIOD STATED IN BOLD FACE TYPE ABOVE.
Claims for defects in material and workmanship covered by this warranty shall be made in writing to the dealer from whom the product was purchased
within the warranty period. Manufacturer may either send a service representative or have the product returned to the Manufacturer at Buyer’s expense
for inspection. If judged by Manufacturer to be defective in material or workmanship, the product will be replaced or repaired at the option of Manufac-
turer, free from all charges except authorized transportation and replacement labor.
NOTE: On doors with one spring, it will be necessary to clamp the torsion tube
with locking pliers to keep counterbalance cables on cable drums BEFORE loos-
ening set screws.
IMPORTANT! Pushing the winding bar too far will cause the counterbalance
cables to fall off the cable drums.
THE REMEDIES OF BUYER SET FORTH HEREIN ARE EXCLUSIVE AND ARE IN LIEU OF ALL OTHER REMEDIES. THE LIABILITY OF
MANUFACTURER, WHETHER IN CONTRACT, TORT, UNDER ANY WARRANTY, OR OTHERWISE, SHALL NOT EXTEND BEYOND ITS
OBLIGATION TO REPAIR OR REPLACE, AT ITS OPTION, ANY PRODUCT OR PART FOUND BY MANUFACTURER TO BE DEFECTIVE IN
MATERIAL OR WORKMANSHIP. MANUFACTURER SHALL NOT BE LIABLE FOR COST OF REMOVAL OR INSTALLATION OR SHALL NOT
BE RESPONSIBLE FOR ANY DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.
Carefully adjust spring tension 1/4 turn. Retighten both set screws in the winding
cone and if required, repeat for the other side. Recheck door balance DO NOT
ADJUST MORE THAN 1/2 TURN FROM THE RECOMMENDED NUMBER
OF TURNS.
This warranty gives you specific legal rights, and you may also have other rights, which may vary from state to state. However, some states do not
allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitations
or exclusions may not apply to you.
© Copyright 2002 Wayne-Dalton Corporation
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If the door still does not operate easily, lower the door into the closed position,
UNWIND THE SPRING(S) FULLY (Reference the insert sheet “Removing the
Old Door/Preparing the Opening” section on Torsion Spring Removal), and re-
check the following the items:
TYPICAL OPERATOR
BRACKET (SUPPLIED
WITH OPERATOR)
2nd HOLE AT 2-3/16”
(56 mm) FROM 1st HOLE
BOTTOM SECTION
(OUTSIDE)
1.) Check the door for level.
2.) Check the torsion tube for level.
3.) Check the track spacing.
BRIDGE POINT
TYPICAL OPERATOR
ARM (SUPPLIED
WITH OPERATOR)
4.) Check the counterbalance cables for equal tension.
5.) Check for track for potential obstruction of the rollers.
6.) Clamp locking pliers onto track and rewind spring(s).
SCREWS (SUPPLIED
WITH OPERATOR)
1st HOLE AT 1”
(25 mm) FROM
BOTTOM OF
SECTION
OUTSIDE
STEP PLATE
IMPORTANT! If door still does not operate properly, then contact a qualified
door agency.
SEE OPERATOR INSTRUCTIONS
FOR DETAILS ON INSTALLATION
21
OPERATOR
MUNTIN
20
INSTALLATION TIPS:
To install the step plate raise the door to a comfortable working height and
secure with locking pliers to the track. Locate the step plate in the center of
any stile on a raised panel door. Make one mark 1” (25 mm) up from the
bottom edge and another mark 2- 3/16” (56 mm) up from the first mark. Drill
a 7/16” (11 mm) hole through the section at each mark and insert the step
plate. Loosely fasten step plate slide to base with (1) 1/4-20 x 1/2” 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. In
the top hole use the #8 x 3/4” screw when attaching step plates to 9200
Foamcore™, use the #8 x 1” screw when attaching step plates to 9600
Thermogard® and use the #8 x 1-1/2” screw when attaching step plates to 9900
Thermowayne™. Tighten 1/4-20 carriage bolt and nut.
1. Follow the installation instructions supplied with your operator.
2. Reinforce top section per manufacturer’s recommendation prior to attaching
operator.
3. Install trolley rail 1” to 1-1/2” (25 - 38 mm) above high arc of top section of
the door.
4. 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 slope down towards rear).
5. The operator bracket must be mounted to the operator muntin on the top
section so it bridges the transition point in section thickness.
SCREW EYE AT 48” TO 50”
(1220 to 1270 mm) FROM FLOOR
WARNING!
NOTE: Step plates are optional on 9900 Thermowayne™, 9600 Thermogard®,
OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND
MONTHLYTHEREAFTER TO ENSURE THAT DOOR REVERSES ON
CONTACTWITH 2 X 4 BOARD LAID FLAT UNDERTHE DOOR. FAIL-
URE TO ADJUST OPERATOR, IF NECESSARY, CAN RESULT IN SE-
VERE INJURYOR DEATH. IFYOUR OPERATOR IS EQUIPPED WITH
PHOTOELECTRIC SYSTEM, THEN THIS MUST BE TESTEDATTHE
SAME TIME TO ENSURE THAT DOOR DOES NOT CLOSE AND A
CLOSING DOOR OPENS IF SYSTEM IS OBSTRUCTED. FAILURE
TO MAKEADJUSTMENTS, IFNECESSARY, CAN RESULT IN SEVERE
INJURY OR DEATH.
and 9200 Foamcore™ door models.
PULL ROPE
#8 x 3/4” SCREW
9200 FOAMCORE
#8 x 1” SCREW
9600 THERMOGARD
#8 x 1-1/2” SCREW
9900 THERMOWAYNE
BOTTOM SECTION
(INSIDE)
TIE PULL ROPE TO
BOTTOM BRACKET
INSIDE STEP
PLATE BASE
INSIDE STEP
PLATE SLIDE
INSTALL FRONT OF
TROLLEY RAIL 1”
TO 1-1/2” (25 - 38
mm) ABOVE HIGH-
ARC OF DOOR
1/4-20 X 9/16”
CARRIAGE BOLT
AND WHIZ NUT
IMPORTANT! ANGLE MUST
BE ATTACHED TO FRAM-
ING MEMBER(S)
#8 x 3/4” SCREW
19
TYPICAL OPERATOR INSTALLATION
Twist the No. 6 screw eye into the wood jamb approximately 48” to 50” (1220 to
1270 mm) from the floor. Tie the pull rope to the screw eye and to the bottom
bracket as shown.
ATTACH OPERATOR
TO CEILING USING
PERFORATED ANGLE
If you are installing an electric operator on your door, the following informa-
tion is provided to ensure proper function of your door/operator installation.
Figure 21 shows a typical means of connecting the operator arm to the opera-
tor stile located in the center of the top section.
ATTACH OPERATOR
RAIL SECURELY TO
SPRING PAD
INSTALL TROLLEY RAIL 1” TO 1-1/2”
(25 - 38 mm) ABOVE DOOR WHEN
FULLY OPEN (RAIL WILL SLOPE
DOWN)
WARNING!
DO NOT INSTALL PULL ROPES ON DOORS WITH ELECTRIC OP-
ERATORS. CHILDREN MAY BECOME ENTANGLED IN THE ROPE
CAUSING INJURY OR DEATH.
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