Wayne-Dalton 9405 Quick Start Manual - Warning

DOOR INSTALLATION 

INSTRUCTIONS

Before installing your door, be certain that you have read and followed all of the instruc-

tions covered in the pre-installation section of this manual. Failure to do so may result in an 

improperly installed door.

NOTE: Reference TDS 160 for general garage door terminology at www.dasma.com.

IMPORTANT: IF THE DOOR WILL BE EXPOSED TO A SIGNIFICANT AMOUNT OF ROAD SALT, 

PAINT THE BARE GALVANIZED BOTTOM WEATHER STEEL RETAINER TO INHIBIT RUSTING.

Vertical Tracks

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NOTE: If you have a wall angle track assembly, skip this step.

NOTE: Refer to Door Section Identification / Parts Breakdown, to determine if you have verti-

cal tracks.

Vertical tracks may or may not have to be cut to the proper length, prior to installing.

IMPORTANT: VERTICAL TRACKS ARE NOT REQUIRED TO BE CUT DOWN IF YOU HAVE DOOR 

HEIGHTS 7’-0” OR 8’-0”.

Determine the radius of your horizontal track.

Refer to the vertical track cutting chart to determine the length needed to be cut off at the top 

of the vertical tracks. Using this measurement, measure and cut the vertical track off at the 

top, as shown. Remove any burrs from the cut edge of vertical track.

Vertical Track Cutting Chart

Horizontal Track Radius

Vertical Track Cut Length

10” Or 12” Radius

Door Height Minus 10”

14” Radius

Door Height Minus 8”

Now, two holes must be drilled into the top of the cut vertical track. Using the illustration 

shown below, mark and drill the hole locations using a 5/16” drill bit. Once the holes have 

been drilled, remove any burrs from the drilled holes. Repeat the same process for the other 

vertical track.

Attaching Flag Angles and Jamb Brackets To 

Vertical Tracks

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NOTE: If you have Angle Mount Track, skip this step.

Hand tighten the left hand flag angle to the left hand vertical track using (2) 1/4” - 20 x 5/8” 

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

NOTE: The bottom jamb bracket is always the shortest bracket, while the center jamb 

bracket is the next tallest. If three jamb brackets per side are included with your door, you will 

have received a top jamb bracket, which is the tallest.

To attach the bottom jamb bracket, locate lower hole of the hole/ slot pattern of the 1st hole 

set on the vertical track. Align the slot in the jamb bracket with the lower hole of the hole/ slot 

pattern. Hand tighten jamb bracket using (1) 1/4” - 20 x 5/8” carriage 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 5/8” carriage bolt and (1) 1/4” - 20 flange hex nut.

If a top jamb bracket was included, hand tighten it to vertical track using the lower hole of the 

hole/ slot pattern in the 3rd hole set and (1) 1/4” - 20 x 5/8” carriage bolt and (1) 1/4” - 20 

flange hex nut.

Attaching Counterbalance Lift Cables and 

Track Rollers

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NOTE: Refer to door section identification, located in the pre-installation section of this 

manual or refer to Breakdown Of Parts.

NOTE: Cable drum assemblies are marked right and left hand.

WARNING 

ENSURE TIGHT FIT OF CABLE LOOP OVER MILFORD PIN TO PREVENT 

COUNTERBALANCE LIFT CABLE FROM COMING OFF THE PIN, WHICH 

COULD ALLOW THE DOOR TO FALL AND RESULT IN SEVERE OR FATAL 

INJURY.

Uncoil the counterbalance lift cables from the cable drum assemblies, making sure you 

place the left hand cable loop on the left hand milford pin of the bottom corner bracket and 

the right hand cable loop on the right hand milford pin of the bottom corner bracket. Insert 

a short stem track roller into the bottom corner brackets and another into the #1 graduated 

end hinges at the top of the bottom section.

NOTE: Larger doors will use long stem track rollers with double graduated end hinges.

NOTE: Verify bottom weather seal is aligned with bottom section. If there is more than 1/2” 

excess weather seal on either side, trim weather seal even with bottom section.

Positioning Bottom Section

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Center the bottom section in the door opening. Level the section using 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.

Attaching Vertical Tracks To Jambs

5

IMPORTANT: IF YOUR DOOR IS TO BE INSTALLED PRIOR TO A FINISHING CONSTRUCTION 

OF THE BUILDING’S FLOOR, THE VERTICAL TRACKS AND THE DOOR BOTTOM SECTION 

ASSEMBLY SHOULD BE INSTALLED SUCH THAT WHEN THE FLOOR IS CONSTRUCTED, NO 

DOOR OR TRACK PARTS ARE TRAPPED IN THE FLOOR CONSTRUCTION.

IMPORTANT: THE TOPS OF THE VERTICAL TRACKS MUST BE LEVEL FROM SIDE TO SIDE. 

IF THE BOTTOM SECTION WAS SHIMMED TO LEVEL IT, THE VERTICAL TRACK ON THE 

SHIMMED SIDE MUST BE RAISED THE HEIGHT OF THE SHIM.

NOTE: Make sure the counterbalance lift cable is located between the track rollers and the 

door jamb.

Starting on the left hand side of the bottom section, remove the nail. Position the left hand 

vertical track assembly over the track rollers of the bottom section and install, as shown. Drill 

3/16” pilot holes into the door jamb for the lag screws.

Loosely fasten jamb brackets and flag angle to the jamb using 5/16” x 2” lag screws. Tighten 

lag screws, securing the bottom jamb bracket to jamb, maintain 3/8” to 5/8” spacing, 

between the bottom section and vertical track. Hang counterbalance lift cable over flag angle. 

Repeat same process for other side.

Attaching Strut(s) To Section

6

NOTE: Refer to Package Contents or Breakdown Of Parts, to determine which type of strut 

you received.

IF YOUR DOOR CAME WITH A STRUT (U - SHAPED): Place the strut (U-shaped) over the 

top rib of the top door section, as shown. Fasten each end of the strut to the end cap with 

(2) 1/4” - 20 x 11/16” self drilling screws. Fasten center of the strut as shown to the rib 

using (2) 1/4” - 14 x 5/8” self tapping screws, one 6” to the left and one 6” to the right of the 

center line of the top door section.

IF YOUR DOOR CAME WITH A STRUT (ASYMMETRICAL): Place the asymmetrical strut 

over the top rib of the top door section, as shown. Fasten each end of the asymmetrical 

strut to the end cap with (2) 1/4” - 20 x 11/16” self drilling screws. Fasten center of the 

asymmetrical strut as shown to the rib using (2) 1/4” - 14 x 5/8” self tapping screws, one 6” 

to the left and one 6” to the right of the center line of the top door section. Fasten both wall 

and the long leg of the asymmetrical strut, as shown using (2) 1/4” - 14 x 5/8” self tapping 

screws every 30 - 36 inches. (Approximately 18 self tapping screws per 18’ asymmetrical 

strut)

IMPORTANT: WHEN SECURING THE ASYMMETRICAL STRUT TO THE TOP SECTION, IT IS 

RECOMMENDED NOT TO INSTALL ANY FASTENERS INTO THE SHORT LEG OF THE ASYM-

METRICAL STRUT.

Attaching Drawbar Operator Bracket

7

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.

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