Wayne-Dalton 9200 Safety Notices, TorqueMaster with idrive, Parts List, Spring Turns, Thermowayne

	Jamb Bracket Schedule						Required Tools			IMPORTANT	MAINTENANCE AND PAINTING
						(1) 7/16” Hex					INSTRUCTION FOR
DOOR	TL-1	TL-2	TL-3
HEIGHT						Head Driver				SAFETY NOTICES	PRE-PAINTED STEEL DOORS
6'0"	BOTTOM	BOTTOM	N/A
64" TRACK	HOLE	HOLE				(1) 7/16” Drill Bit (Step Plate)		(2) Locking Pliers
(1626 mm)
											MAINTENANCE
6'5"	MIDDLE	BOTTOM
									Wayne-Dalton Corp.
											While factory-applied finishes for steel garage doors are so durable that they will last many years longer than ordinary
69" TRACK			N/A
	HOLE	HOLE
(1753 mm)									P.O. Box 67		paints, it is desirable to clean them thoroughly on a routine basis. Apparent discoloration of the paint may occur when
								(1) 7/16” Wrench
6'6"	MIDDLE	BOTTOM			TL-3				Mt. Hope, Ohio 44660		it has been exposed in dirt-laden atmospheres for long periods of time. Slight chalking may also cause some change in
70" TRACK			N/A	HOLES							appearance in areas of strong sunlight. A good cleaning will generally restore the appearance of these coatings and render
	HOLE	HOLE							Read these instructions carefully before attempting installation. If in question about any of the proce-
(1778 mm)
						(1) Electric Drill					repainting unnecessary. An occasional light cleaning will also help maintain an aesthetically pleasing appearance. To
6'8"									dures, do not perform the work. Instead, have a qualified door agency do the installation or repairs.
	BOTTOM	BOTTOM				with Clutch					maintain the original finish of the garage doors, the only regular maintenance necessary is that of annual washing. Mild
72" TRACK			N/A
	HOLE	HOLE									solutions of detergents or household ammonia will aid in the removal of most dirt, and the following are recommended
(1829 mm)								(1) Screw Driver
											levels:
						Gloves			1. Wear protective gloves during installation to avoid possible cuts from sharp metal edges.
7'0"
	MIDDLE	BOTTOM						(Phillips Blade)
76" TRACK			N/A				(1) Hammer				One cup of Tide™, or other common detergents, which contain less than 0.5% phosphate, dissolved into five gallons
	HOLE	HOLE
(1930 mm)									2. It is always recommended to wear eye protection when using tools, otherwise serious eye injury could		of warm water. NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in
7'3"	BOTTOM	BOTTOM	BOTTOM		TL-2				result.		general cleaning of garage doors. CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.
79" TRACK
	HOLE	HOLE	HOLE		HOLES
(2007 mm)							(1) Screw Driver		3. Avoid installing your new door on windy days. Door could fall during the installation and cause		SURFACE PREPARATION FOR PAINTING
7'6"	MIDDLE	MIDDLE	MIDDLE			(1) Step Ladder	(Standard Blade)		damage and personal injury.		Wax on the surface must be removed or paint peeling/flaking will result. To remove this wax, it will be necessary to
82" TRACK	HOLE	HOLE	HOLE					Safety Glasses			lightly scuff the surface with a gray (not green!) 3M ScotchBrite pad saturated with soapy water. A final wipe and rinse
(2083 mm)
							(50) 1-1/2”		4. If the door is to be electrically operated at any time, all pull ropes MUST be removed to prevent injury		should be done with clean water only, to remove any loose dust or soap film.
7'9"
	MIDDLE	MIDDLE	MIDDLE				Common Nail		or death to children who may become entangled in the rope. The locking mechanism MUST also be		Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or
85" TRACK
	HOLE	HOLE	HOLE								No. 400 sand paper to create a smoother surface. Care must be taken to not expose the substrate under the paint (see
(2159 mm)									disengaged.
											Note No. 2). Once this exposed condition exists, the likelihood for rusting is greatly increased. See the following
8'0"
					TL-1						paragraph if the metal substrate is observed.
4 SECTIONS	MIDDLE	MIDDLE	MIDDLE			(1) Level (2’ Minimum Length)			5. Operate door ONLY when properly adjusted and free of obstructions.
88" TRACK	HOLE	HOLE	HOLE		HOLES						Exposed substrate must be treated to prevent rust from forming (see Note No. 2). Sand the exposed area lightly and
(2235 mm)								(1) Socket Wrench	6. Should the door become hard to operate or completely inoperative, a qualified door agency should		paint with high quality metal primer to protect from corrosion. Follow drying time on primer can label before applying
8'0"
								with 7/16”, 1/2”, 9/16”	correct the problem to prevent damage to the door or serious personal injury.		topcoat.
5 SECTIONS	TOP	TOP	MIDDLE
								sockets			The surface to be re-coated must not be to smooth or the repaint material will not adhere to it (see Note No. 2). It is
88" TRACK	HOLE	HOLE	HOLE

	10/02		1.Rev
			.necessary not if plied
-sup be not will listed parts some model, door the on Depending NOTE:
SEPARATELY SOLD			SUPPORT REAR (X)
SEPARATELY SOLD			OPERATOR ™drivei (W)
282335 #			GEAR WORM TOOTH 36 (V)
287721 #	SPRING) (DOUBLE (LH) .ASM COVER COUNTER
287722 #			(RH) .ASM COVER COUNTER (U)
284035 #			GEAR COUNTER (T)
280066 #			SPRING) (SINGLE SHAFT WINDING LOOSE (S)
282340 #			(RH) BRACKET END (R)
282937 #			(LH) BRACKET END (Q)
280086 #			(PAIR) .ASM /DRUM CABLE (P)
ASSEMBLY 1			TUBE TORQUEMASTER (O)
		List Parts drive™i with TorqueMaster™ See NOTE:
		SYSTEM COUNTERBALANCE TORQUEMASTER™
292538 #			(LEFT) ANGLE .HORIZ 80” (N)
292539 #			(RIGHT) ANGLE .HORIZ 80” (M)
292536 #			ANGLE .HORIZ 15/16”-21 (L)
240383 #			7/8”)-19 (RIGHT, FLAGANGLE 15” R (K)
240382 #			7/8”)-19 (LEFT, FLAGANGLE 15” R (J)
292531 #			1/2”)-18 (RIGHT, FLAGANGLE 12” R (I)
292530 #			1/2”)-18 (LEFT, FLAGANGLE 12” R (H)
PAIR 1			TRACK HORIZONTAL (G)
261967 #			BRACKET JAMB 3-TL (F)
261966 #			BRACKET JAMB 2-TL (E)
261965 #			BRACKET JAMB 1-TL (D)
PAIR 1			TRACK VERTICAL (C)
#154489			ROLLER (B)
158046 #			SLIDE BRACKET TOP (A2)
158044 #			BASE BRACKET TOP (A1)

302868 .NO PART

274884 #	ROPE PULL 60” (Z2)
100362 #	EYE SCREW 6 # (Z1)
296246 #	.ASM BRACKET CENTER (Y)
	List Parts Alternate

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	(2235)						(1) Pliers			7. DO NOT PERMIT children to play with the garage door or the electrical controls. Fatal injury could	advisable to test a representative area to evaluate adhesion. If poor adhesion is observed, the surface must be abraded by
									(2 or 3) Saw Horses or other supports for placing		sanding or buffing using grades mentioned above. Care must be taken to not expose the substrate under the paint.
										result, should the child become entrapped between the door and the floor.
	NOTE: Jamb brackets are stamped for identification.							(1) Tape Measure	sections on while assembling
											PAINTING
										8. To prevent serious injury or death, avoid standing in the open doorway or walking through the
											After the surface has been properly prepared it must be allowed to dry thoroughly, then coated immediately with a
										doorway while the door is moving.
											premium quality latex house paint. Follow the paint label directions explicitly. Oil base paint is not recommended.
a	1/4”-20 Flanged	c	1/4”-20 x 5/8”	f	1/4”-20 x 11/16” Self Drilling Screw		h	5/16” x 1-5/8” Hex Head Lag Screw	p 1/4” x 2” Slotted Hex Head Lag Screw	9. Door is constantly under EXTREME SPRING TENSION. To prevent possible serious injury or death,	Please note that if substrate is exposed, painting with latex paint may cause accelerated rusting of steel.
	Hex Nut				#300723			#100292			NOTES:
	#100279		Carriage Bolt						#284454	adjustments, repairs, removal or installation, ESPECIALLY of SPRING ASSEMBLIES, CABLES or
			#262617							BOTTOM CORNER BRACKETS, should be performed ONLY by qualified door service people.	1. Repainting of finish painted steel doors cannot be warranted as this condition is totally beyond door
										10. If your existing garage door opener does not have a reversing mechanism, you should consider	manufacturer’s control.
											2. If the steel door surface has a finish painted textured surface representing wood grain, stucco, etc., this step
										purchasing one that has up to date safety features. These features can prevent opener related property	should not be attempted as danger of exposing substrate is greatly increased.
										damage or personal injury.	3. Consult a professional coatings contractor if in doubt about any of the above directions.
											4. Follow directions explicitly on the paint and solvent container labels for proper applications of coatings
										11. Check all bolted connections monthly during the lifetime of the door to prevent damage or personal	and disposal of containers. Pay particular attention to those directions involving acceptable conditions in which to
										injury caused by loose connections.	paint.
b 3/8”-16 Hex Nut		e			g	1/4”-14 x 5/8” Self Tapping		1/4” x 1-1/2” Slotted Hex Head			DÉCOR LITES ACRYLIC GLAZING CLEANING INSTRUCTIONS:
			3/8”-16 x 3/4” Truss Head Bolt			Screw	m Lag Screw		q #6-20 x 1/2” Plastifast	12. Definition of key words used in this manual:	1. To clean acrylic glazing wash with plenty of nonabrasive soap or detergent and water. Use the bare hand to feel
	#100313		#154531			#236565		#269025
									(Disconnect Handle)	WARNING! -- Indicates a potentially hazardous situation which, if not avoided, could result	and dislodge any caked dirt or mud. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not
									#296940		use hard or rough cloth that will scratch the acrylic glazing. Dry with a clean damp chamois.
										in serious injury or death.
											2. Grease and oil may be removed with kerosene or a good grade of naphtha (No aromatic content.). Users of these
										IMPORTANT! -- Required step for safe and proper door operation.	solvents should become familiar with their properties to handle them safely.
											3. Do not use: Window cleaning fluids, scouring compounds, gritty cloths, leaded or ethyl gasolines, or
										NOTE: -- Information assuring proper installation of the door.	solvents such as alcohol, acetone, carbon tetrachloride, etc.
										© Copyright 2002 Wayne-Dalton Corp.	© Copyright 2002 Wayne-Dalton Corp.

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		com.dalton-wayne.www
Manual Owners and Instructions Installation
Spring Double and Spring Single - TorqueMaster™
Thermowayne™ 9900	Thermogard® 9600	Foamcore™ 9100/9200

...CONTINUED INSTALLATION INSTRUCTIONS		ALTERNATIVE INSTALLATIONS
20								9900 Thermowayne™ 9600 Thermogard		®
	12A					TYPICAL TROLLEY OPERATOR INSTALLATION
Locate right hand drum wrap. Slide back half of the drum wrap behind drum placing the right end wall between the drum	If you are not installing the idrive™ operator on your garage door, you must
					If you are installing an electric operator on your door, the following information is				9100/9200 Foamcore™
and flagangle. Close front half of the drum wrap around drum, engage inboard snap and press firmly until a distinct snap	install the center bracket bushing assembly. Follow these instructions for a		12A		provided to ensure proper function of		your door/operator installation. Figure below
is felt. Outboard catch must be engaged as shown. Confirm both snap and catch are fully engaged by lightly tugging against	non-idrive™ operated garage doors.
					shows a typical means of connecting the operator arm to the operator stile located in
them. Repeat for the left side.	TorqueMaster™	springs come lubricated and pre-assembled inside the torque			the center of the top section.
	tube. To install, lay the torque tube on the floor in front of the door with the								LIFETIME LIMITED WARRANTY
21	labeled end to the left. Slide the center bracket/bushing assembly onto the							Wayne-Dalton Corp.
Hold the door down to prevent it from rising unexpectedly in the event the spring was overwound and carefully remove	torque tube, from the right hand side, toward the center. Shake the					TYPICAL OPERATOR		P.O. Box 67, Mt. Hope, Ohio
	TorqueMaster™ tube gently to extend the winding shafts out about 5” on both					BRACKET (SUPPLIED		44660
the locking pliers from the vertical tracks. Raise the door until the top section and half of the next section are in a horizontal						WITH OPERATOR)		www.wayne-dalton.com
	ends. Single spring TorqueMaster will only have the right hand spring. Slide
position. Do not raise door any further since rear of horizontal track is not yet supported.
	center bracket/bushing assembly from the right side to the center of the torque							The Manufacturer warrants the 9900 THERMOWAYNE, 9600 THERMOGARD and 9200 FOAMCORE insulated garage door for as long as you
	tube.
								own the door from the time of installation against structural failure (rendering the door inoperable) of the door sections due to separation/ degradation
WARNING!	IMPORTANT! Right and left hand are always determined from inside the
						BRIDGE POINT		of foam insulation. Other conditions and exceptions as contained herein apply.
RAISING DOOR FURTHER CAN RESULT IN DOOR FALLINGAND CAUSE SEVERE INJURY OR DEATH.	building looking out.					SCREWS (SUPPLIED	TYPICAL OPERATOR ARM	The Manufacturer warrants the steel skin of the 9900 THERMOWAYNE, 9600 THERMOGARD and 9200 FOAMCORE insulated garage door for
	12B		12B				(SUPPLIED WITH OPERA-
						WITH OPERATOR)		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
Now clamp a pair of locking pliers to the vertical tracks just above the second roller on one side, and just below the second							TOR)
	When installing a DoorMaster™ operator replace the bushing with the drive							exceptions contained herein apply.
roller on the other side. This will prevent the door from raising or lowering while installing the rear support. Using
	gear (located in DoorMaster™ package).						OPERATOR	The Manufacturer warrants the garage door hardware and track, excluding springs, for as long as you own the door against defects in workmanship or
perforated angle, 2” lag screws and 5/16 bolts with nuts (may not be supplied), fabricate rear support for horizontal tracks.							STILE
					SEE OPERATOR INSTRUCTIONS
								material from time of installation.
Attach horizontal tracks to the rear supports with 5/16-18 x 1-1/4” hex bolts and nuts (may not be supplied). Horizontal					FOR DETAILS ON INSTALLATION
tracks must be level and parallel with door.						INSTALLATION TIPS:		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.
WARNING!					1.	Follow the installation instructions supplied with your operator.
KEEP HORIZONTALTRACK PARALLELAND WITHIN 3/4” OF DOOR EDGE, OTHERWISE DOOR COULD					2. Reinforce top section per manufacturer’s recommendation prior to attaching
					operator. See illustration below.
FALL, RESULTING IN SERIOUS INJURY OR DEATH.								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
					3.	Install trolley rail 1/2” to 1-1/2” (13 - 38 mm) above high arc of top section of the
Permanently attach the vinyl weather stripping to both door jambs and the header. Avoid pushing vinyl into force of door.					door.			warranty applies to residential property only and is not valid on commercial or rental property.
	16		16		4. Mount operator to ceiling so that 1” to 1-1/2” (25 - 38 mm) clearance is maintained			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
Now, lift the door and check it’s balance. Adjust, if door lifts by itself (also hard to pull down) or if door is difficult to lift				m
					between trolley rail and top section when door is fully open (trolley rail will slope down
								for ONE YEAR from the time of installation.
(too easy to pull down). Anytime spring adjustments are made you must loosen the lock nuts to begin with and retighten	To locate the center bracket, mark the header halfway between the flagangles				towards rear).
both lock nuts afterwards. To adjust spring(s), only add or remove 1/4 turn on the counter reading at a time. Adjust both	and level the TorqueMaster tube. Fasten the metal bracket to the header				5.	The operator bracket must be mounted to the operator stile on the top section so		The Manufacturer shall, upon notification, correct any nonconformity at its option, by repairing, replacing, or refunding original purchase price of any
sides equally.	using (2) 1/4 x 1-1/2” lag screws.				it bridges the transition point in section thickness.			defective part(s). This warranty covers material only and excludes all other charges incurred.
IMPORTANT! Do not add or remove more than 1 spring turn from specified amount.					6. Attach operator rail to spring pad.			NO EMPLOYEE, DISTRIBUTOR, OR REPRESENTATIVE IS AUTHORIZED TO CHANGE THE FOREGOING WARRANTIES IN ANY WAY OR
					7.	Attach operator to ceiling using perforated angle.
								GRANT ANY OTHER WARRANTY ON BEHALF OF MANUFACTURER.
If the door still does not operate easily, lower the door into the closed position, UNWIND SPRING(S) TO ZERO, and	STEP PLATES	OPTIONAL ACCESSORY		m	8.	IMPORTANT! Angle must be attached to framing member(s).		The Manufacturer shall not be responsible for any damage resulting to or caused by its products by reason of installation, improper storage, unautho-
						WARNING!
	Make one mark 1” (25 mm) up from the center of bottom edge and							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.
recheck the following items:
	another mark 2- 3/16” (56 mm) up from the first mark. Drill a 7/16”				OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY			The 9900 THERMOWAYNE, 9600 THERMOGARD and 9200 FOAMCORE warranty becomes null and void if the door is punctured with any hole
1.) Check the door for level.
								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

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	TorqueMaster™ with idrive™
	Parts List
	(O) TORQUEMASTER TUBE	1 ASSEMBLY
	(P) CABLE /DRUM ASM. (PAIR)	# 280086
	(Q) END BRACKET (LH)	# 282937
	(R) END BRACKET (RH)	# 282340
	(S) LOOSE WINDING SHAFT (SINGLE SPRING)	# 280066
	(T) COUNTER GEAR	# 284035
	(U) COUNTER COVER ASM. (RH)	# 287722
O	COUNTER COVER ASM. (LH) (DOUBLE SPRING)	# 287721
	(V) 36 TOOTH WORM GEAR	# 282355
	(W) idrive™ OPERATOR	SOLD SEPARATELY
	(Y) CENTER BRACKET ASM. (NON-idrive™ OPERATED)	# 296246
	NOTE: See idrive™ Main Installation and Owners Manual for idrive™ parts
	NOTE: Single Spring TorqueMaster™ shown in illustration.
	W

2.) Check the TorqueMaster™ tube and flagangles for level and plumb.			(11 mm) hole through the section at each mark and insert the		THEREAFTER TO ENSURE THAT DOOR REVERSES ON CONTACT WITH 2 X			circumstances such as normal wear, damage from corrosive fumes or substances, fire, condensation, vandalism, acts of God, or other causes beyond
					4 BOARD LAID FLAT UNDER THE DOOR. FAILURE TO ADJUST OPERA-
3.)	Check the distance between the flagangles - must be door width plus 3-3/8” to 3-1/2”.		outside step plate. Loosely fasten step plate slide to base with (1)					Manufacturer’s control, nor replacement or repair labor.
			1/4-20 x 5/8” carriage bolt and nut. Align inside step plate holes and		TOR, IF NECESSARY, CAN RESULT IN SEVERE INJURY OR DEATH. IF
4.)	Check the counterbalance cables for equal tension - loosen set screws and adjust if necessary.
			fasten from inside using the #8 screws provided. Install one #8 x 3/		YOUR OPERATOR IS EQUIPPED WITH PHOTOELECTRIC SYSTEM, THEN			THIS WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS WARRANTY ACT. NO WARRANTIES,
5.)	Rewind the spring(s).
					THIS MUST BE TESTED AT THE SAME TIME TO ENSURE THAT DOOR DOES
			4” screw in the bottom step plate hole. The screw in the top hole					EXPRESSED OR IMPLIED, (INCLUDING, BUT NOT LIMITED TO, THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICU-
6.)	Make sure door isn’t rubbing on jambs.
			varies with door models. Use the screw size required for your		NOT CLOSE AND A CLOSING DOOR OPENS IF SYSTEM IS OBSTRUCTED.			LAR PURPOSE), SHALL EXTEND BEYOND THE APPLICABLE TIME PERIOD STATED IN BOLD FACE TYPE ABOVE.
					FAILURE TO MAKE ADJUSTMENTS, IF NECESSARY, CAN RESULT IN SE-
NOTE: As a safety feature, the right hand end bracket cannot be disassembled for service until the spring is completely			model door.					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
					VERE INJURY OR DEATH.
			a) #8 x 3/4” screw for Model 9100 and 9200
unwound and the counter cover reads zero.								within the warranty period. Manufacturer may either send a service representative or have the product returned to the Manufacturer at Buyer’s expense
			b) #8 x 1” screw Model 9600					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-
After door installation is completed, refer to the idrive™ owner’s manual, starting at the		PRE-OPERATION INSTALLA-	c) #8 x 1-1/2” screw Model 9900					turer, free from all charges except authorized transportation and replacement labor.
TION section to complete the opener installation.			Tighten 1/4-20 carriage bolt and nut.	6		3	8	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
			PULL ROPE					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
			Screw the No. 6 screw eye into the wood jamb approximately 48”					BE RESPONSIBLE FOR ANY DIRECT, INDIRECT, SPECIAL OR CONSEQUENTIAL DAMAGES OF ANY NATURE.

Spring Turns

Door Height = Spring Turns

6’0” = 14 turns 6’-3” = 14-1/2 turns 6’-5” = 15 turns 6’-6” = 15 turns 6’-8” = 15-1/2 turns 6’-9” = 15-1/2 turns 7’-0” = 16 turns 7’-3” = 16-1/2 turns 7’-6” = 17 turns

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to 50” (1220 to 1270 mm) from the floor. Tie the pull rope to the			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
screw eye and to the bottom bracket as shown.		7	allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitations
	WARNING!		or exclusions may not apply to you.
		5

7’-9” = 17-1/2 turns 8’-0” = 18 turns

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DO NOT INSTALL PULL ROPES ON DOORS WITH ELEC-		© Copyright 2002 Wayne-Dalton Corporation
TRIC OPERATORS. CHILDREN MAY BECOME EN-
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TANGLED IN THE ROPE CAUSING INJURY OR DEATH.

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