Wayne-Dalton Installing Wayne Dalton Garage Door Track Systems: A Step-by-Step Guide

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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.

If removing an existing door, carefully follow the directions given on the insert sheet instruction in the portion titled “Removing the Old Door”.

WARNING!

REMOVAL OF AN EXISTING DOOR CAN BE DANGEROUS. FOLLOW INSERT SHEET INSTRUCTIONS CAREFULLY, OTHERWISE SERIOUS INJURY OR DEATH COULD RESULT.

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”.

FLAGANGLE

ALIGN TAB INTO

TOP HOLE IN

TRACK AND

TWIST UP UNTIL

PARALLEL WITH

TRACK

VERTICAL

1

TRACK

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.

80” HORIZONTAL ANGLE

2

COUNTERBALANCEMILFORD

CABLE FOR LEFT HAND PIN

DRUM

CABLE LOOP

 

 

BOTTOM

 

 

 

SECTION

 

LEFT HAND

4

ROLLER

BOTTOM

 

BRACKET

 

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.

IMPORTANT! Right and left hand is always determined from inside the building looking out.

VINYL WEATHER STRIPPING TEMPORARILY NAILED TO JAMBS (REFER TO INSERT SHEET ON PREPARING THE OPENING.)

LEVEL

BOTTOM ASTRAGAL

5

 

TOP BRACKET

TOP SECTION

 

SLIDE

ROLLER

RIB

 

 

 

1ST SET OF HOLES ON

(2) 1/4-20

 

CARRIAGE BOLTS

9900 THERMOWAYNE™

AND NUTS

2ND SET OF HOLES ON

TOP BRACKET

(4) 1/4-20 x 5/8”

 

 

9600 THERMOGARD®

 

 

 

SELF TAPPING

8

3RD SET OF HOLES ON

SCREWS

 

9200 FOAMCORE™

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.

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3” U-BAR

1/4-20 x 5/8” SELF

DRILLING SCREW

 

 

 

 

TOP SECTION

FOAMCORE™ II

 

(MODEL 9200)

 

TOP RIB

 

TOP SECTION

 

 

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.

(2)5/16” x 1-5/8”

LAG SCREW

TOP SECTION

NOTE: CABLE SHOULD

22-1/2”

HORIZONTAL ANGLE

HORIZONTAL TRACK

ALIGN TABS INTO SLOTS, PUSH TOGETHER AND TAP FORWARD WITH HAMMER

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.

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

FLAGANGLE

BE BETWEEN TRACK

10

AND DOOR AND

 

 

BEHIND ROLLERS

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.

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.

NOTE: For larger size doors, a full length horizontal angle is already spot welded to the horizontal track.

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).

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.

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Contents Track Horizontal Angle Flagangle#2 END Hinge #1 END Hinge Bottom Bracket Horizontal Track Maintenance Acrylic Glazing Cleaning InstructionsSurface Preparation for Painting PaintingSide Lock Installation Carriage Bolts Thermowayne Nuts ND SET of Holes on TOP BracketThermogard Self Tapping RD SET of Holes on Screws Foamcore Drilling ScrewTruss Head Bolt & Nuthorizontal Angle FlagangleCenter Bearing Bracket Horizontal Pencil Line Spring WarningLabel Spring PAD Over MasonryLAG Screws not Supplied Bolt and NUT Not Supplied Extend Bolt Through TrackTypical Operator Installation Bottom Section OutsideBottom Step Plate

9600 Thermoguard, 9900 Thermowayne, 9200 Foamcore specifications

Wayne-Dalton offers a range of high-performance garage doors designed for durability, insulation, and aesthetic appeal. Among their standout products are the 9200 Foamcore, 9900 Thermowayne, and 9600 Thermoguard models. Each of these doors is engineered to meet various needs, combining advanced technologies with attractive designs.

The Wayne-Dalton 9200 Foamcore door features a unique construction that integrates a polyurethane foam core, providing excellent thermal insulation while minimizing weight. This door is ideal for homeowners looking for energy efficiency, as the polyurethane foam offers an R-value of up to 16.9. The 9200’s steel exterior is available in a variety of colors and finishes, enabling customization that enhances curb appeal. The door’s low-maintenance surface makes it resistant to dents and scratches, while its construction helps to reduce noise and improve security.

The 9900 Thermowayne is another exceptional model, designed specifically for energy efficiency and functionality. This model features a triple-layer construction combining an outer steel layer, a polyurethane insulation core, and an inner steel layer, resulting in an R-value of up to 18.4. The Thermowayne doors are also equipped with an exclusive 2-inch thick door design that minimizes heat transfer, making it an excellent option for regions with extreme temperatures. The 9900 series comes in numerous panel designs and colors, allowing homeowners to select a configuration that complements their home’s architecture. Additionally, the door is finished with a durable paint that resists fading and is easy to clean.

Finally, the Wayne-Dalton 9600 Thermoguard model takes insulation to the next level with its double-layer construction. This door combines a CFC-free polystyrene core between two layers of steel, providing an exceptional R-value of up to 19. The Thermoguard’s design not only enhances thermal performance but also contributes to sound attenuation, making it suitable for homes located in noisy environments. The 9600 series is available in various styles, ensuring a perfect match for any home. Its weather seals and reinforced structure contribute to its longevity and resistance to the elements.

In summary, Wayne-Dalton’s 9200 Foamcore, 9900 Thermowayne, and 9600 Thermoguard garage doors offer exceptional insulation, durability, and aesthetic options to meet diverse homeowner needs. By integrating advanced technology and high-quality materials, these doors not only enhance energy efficiency but also elevate the overall look of a home.