Wayne Dalton Torquemaster 46 Users Manual

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8000 Series, Model 46
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.
Part No. 328739

REV1 08/03/2009

Table of Contents
Important Safety Instructions............................................. 2
Package Contents...........................................................3-4
Door Section Identification................................................. 4
Tools Required................................................................... 5
Preparing The Opening...................................................... 6
Installation . .................................................................7-31
Optional Installations..................................................32-36

Side Lock........................................................ 32

Alternative Step Plate...................................... 33

Pull Rope......................................................... 33

Trolley Operator............................................... 34
Maintenance.................................................................... 35

Cleaning.......................................................... 35

Painting Instructions........................................ 35
Warranty.......................................................................... 36
Dealer Locator Information.............................................. 36

Definition of key words used in this manual:

WARNING

Indicates a potentially hazardous
situation which, if not avoided, could
result in severe or fatal injury.
CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT
FROM FAILURE TO FOLLOW INSTRUCTIONS.
IMPORTANT: Required step for safe and proper
door operation.
NOTE: Information assuring proper installation of the door.

WARNING

To Avoid possible injury, 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.
1. Read and follow all installation instructions.
2. Wear protective gloves during installation to avoid possible
cuts from sharp metal edges.
3. It is always recommended to wear eye protection when using
tools, otherwise severe or fatal eye injury could result.
4. Avoid installing your new door on windy days. Door could
fall during the installation causing severe or fatal injury.
5. Doors 12’-0” wide and wider should be installed by two
persons, to avoid possible injury.
6. Operate door ONLY when it is properly adjusted and free from
obstructions.
7. If a door becomes hard to operate, inoperative or is damaged,
immediately have necessary adjustments and/or repairs
made by a trained door system technician using proper tools
and instructions.
8. DO NOT stand or walk under a moving door, or permit
anybody to stand or walk under an electrically operated door.
9. DO NOT place fingers or hands into open section joints when
closing a door. Use lift handles/gripping points when operating
door manually.
10. DO NOT permit children to operate garage door or door
controls. Severe or fatal injury could result, should the child
become entrapped between the door and the floor.
11. Due to constant extreme spring 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 possible
severe or fatal injury, have any such work performed
by a trained door systems technician using proper tools and
instructions.
12. On electrically operated doors, pull down ropes must be
removed and locks must be removed or made inoperative in
the open (unlocked) position.
13. Top section of door may need to be reinforced when attaching
an electric opener. Check door and/or opener manufacturer’s
instructions.
14. VISUALLY inspect door and hardware monthly for worn and/or
broken parts. Check to ensure door operates freely.
15. Test electric opener’s safety features monthly, following
opener manufacturer’s instructions.
16. NEVER hang tools, bicycles, hoses, clothing or anything else
from horizontal tracks. Track systems are not intended or
designed to support extra weight.

After installation is complete, fasten this manual
near garage door.
2
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Package Contents
NOTE: Depending on the door model, some parts listed will not be supplied if not necessary.
rear supports may or may not be included with your door.

(2) Horizontal Tracks with attached horizontal angle RH/LH

(1) TorqueMaster® Spring TUBE

door sections (as required)

jamb brackets
(as required)

right & left
Drum Wraps

(1) Loose Winding Shaft
(SINGLE SPRING only)

right and left cable
drum assemblies

right and left
bottom brackets

(1) Center Bracket
assembly

U-BAR
(as required)

right & left
End Brackets

Rollers
(as required)

(2) STEP PLATEs

#1, #2, #3 & #4
hinges (as required)

(2) TOP BRACKET
Bases

(2) TOP BRACKET
Slides

(2) LIFT Handles
& spacers

weather seal &
nails (if included)

8000 Series, Model 46
TorqueMaster® - Single and Double Spring
Installation Instructions and Owner’s Manual
Portland Source Plant

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 qualified door agency
do the installation or repairs.
© Copyright 2005 Wayne-Dalton Corp.

Part No. 323295

New 11/08/2005

manual

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#6 screw eye and pull
rope (if included)

3
Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Package Contents Continued...

5/16”- 18 Hex Nuts
(as required)

(2) 3/8”- 16
Hex Nuts

1/4”- 20 x 5/8” Carriage
Bolts (as required)

1/4”-20 x 11/16” Self Drilling
Screws (as required)

1/4”- 20 HEX Nuts
(lift handle)

1/4”- 20 x 5/8” Carriage
Bolts (as required)

1/4”- 20 x 7/8” Self Drilling
Screws (as required)

(2) 1/4” x 2-1/2” carriage bolts (lift handle)

1/4”- 20 Flanged Hex
Nuts (as required)

(2) 3/8”- 16 x 3/4”
hex head bolts

(2) 1/4”- 20 X 5/8” TAMPERresistant Screws

1/4”- 14 x 5/8” Self Tapping
Screws (as required)

5/16” X 2” HEX head LAG screws (as required)

(2) 1/4” x 2-3/4” carriage bolts

Door Section Identification
Tools Needed:

The bottom section can be
identified by the factory attached
bottom astragal and the bottom bracket
warning labels on each end stile. This
section is always the 1st section on
four and five section doors.

Top Section

The lock section may have a yellow
and black warning label on the right
side of the section. This section is
always the 2nd section from the bottom
of the door.

Intermediate ii Section (5 section doors only)

The intermediate i section may
have a warning label attached to either
right or left hand endstile of the section.
This section is always the 3rd section
from the bottom of the door.

Intermediate i Section

The intermediate ii section is
always the 4th section on a five section
door.

Lock Section

warning label

Bottom Bracket
warning Labels

The Top section is always the 4th
section on four section door and the 5th
section on five section door.
astragal

Bottom Section

4
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Tools Required

power drill

Phillips Head
Screwdriver

pencil

1/2”, 9/16”, 5/8”
& Socket

(2) sawhorses

ratchet Wrench

Pliers/wire cutters

1/8”, 3/16”, 9/32”,
5/16”, 1/2” drill bits

vice grips

7/16”, 1/2” socket
driver

1/4”, 3/8”, 7/16”, 1/2” &
9/16” Wrenches

Hacksaw

Tape Measure

(2) vice clamps

3” extension

Flat Tip Screwdriver

Safety Glasses

gloves

level

hammer

Torx Bit

Step Ladder

Removing an Existing Door
Counterbalance spring tension must always be released before any attempt is made to start removing an existing door.

WARNING
A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE SEVERE OR FATAL INJURY. TO AVOID
INJURY HAVE A TRAINED DOOR SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS, RELEASE
THE SPRING TENSION.
For detailed information see supplemental instructions “removing an existing door/preparing the opening”. These instructions are
available at no charge from Wayne-Dalton Corp., P.O. Box 67, Mt. Hope, OH 44660, or at www.wayne-dalton.com.

5
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Preparing the Opening
Tools Needed:
Recommended
tools from
page 5

Failure to
securely attach a
suitable mounting pad to structurally
sound framing could cause springs to
violently pull mounting pad from wall,
resulting in severe or fatal injury.

suitable mounting
surface 2” x 6”
lumber minimum

header board
2” x 6” lumber
preferred

WARNING

door height
level header
plumb jambs

If you just removed your existing door or you are installing a
new door, complete all steps in PREPARING THE OPENING.

door
width

To ensure secure mounting of track brackets, side
and center brackets, or steel angles to new or retro-fit
construction, it is recommended to follow the procedures
outlined in DASMA Technical Data Sheets #156, #161 and
#164 at www.dasma.com.
The inside perimeter of your garage door opening should
be framed with wood jamb and header material. The jambs
and header must be securely fastened to sound framing
members. It is recommended that 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 headroom applications, the jambs should
extend to the ceiling height. Minimum side clearance
required, from the opening to the wall, is 3-1/2” (89 mm).

headroom
backroom

header

jamb

IMPORTANT: Closely inspect jambs, header and mounting
surface. Any wood found not to be sound, must be replaced.

WEATHER SEAL

For TorqueMaster® Plus counterbalance systems, a suitable
mounting pad (2” x 4”) must be firmly attached to the wall,
above the header at the center of the opening.

jamb

NOTE: Drill 3/16” pilot holes in the mounting pad to avoid
splitting the lumber, and attach mounting pad with lag
screws of appropriate length. Do not attach the mounting
pad with nails.

weather
seal

Weather Seal (May Not Be Included):
Cut or trim the weather seal (if necessary) to fit the header
and jambs.
For fully adjustable track: Align the header seal 1/8” to
1/4” inside the header and temporarily secure it to the
header with equally spaced nails. Next, fit the jamb seals
up tight against the header seal and 1/8” to 1/4” inside the
jamb. Temporarily secure the jamb seals with equally spaced
nails. Equally space nails approximately 12” to 18” apart.
This will keep the bottom section from falling out of the
opening during installation.
NOTE: Do not permanently attach weather seal to the jamb
at this time.
HEADROOM REQUIREMENT: Headroom is defined as the
space needed above the top of the door for tracks, springs,
etc. to allow the door to open properly. If the door is to be
motor operated, 2-1/2” (64 mm) of additional headroom is
required.
NOTE: 6” LHR Conversion Kit is available for 12” track radius
only. Contact your local Wayne-Dalton dealer.
BACKROOM REQUIREMENT: Backroom is defined as the
distance needed from the opening back into the garage to
allow the door to open fully.

jamb 1/8” to 1/4”

headroom requirement
TRACK TYPE

TorqueMaster® Plus

10”, 12”

10”

14”

12”

3-1/2” LHR

6”

LHR Kit

6 1/2”

backroom requirement
DOOR
HEIGHT
6’5”
6’5”
6’6”
6’6”
7’0”
7’0”
7’6”
7’6”
8’0”
8’0”

TRACK
10”, 12”, 14” Radius
Low Headroom
10”, 12”, 14” Radius
Low Headroom
10”, 12”, 14” Radius
Low Headroom
10”, 12”, 14” Radius
Low Headroom
10”, 12”, 14” Radius
Low Headroom

MANUAL
MOTOR
LIFT
OPERATED
89”
125”
101”
125”
90”
125”
102”
125”
96”
125”
108”
125”
102”
137”
114”
137”
108”
137”
120”
137”

6
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

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.
IMPORTANT: STAINLESS STEEL OR PT 2000 COATED LAG SCREWS MUST BE USED WHEN INSTALLING CENTER BEARING BRACKETS,
END BRACKETS, JAMB BRACKETS, OPERATOR MOUNTING/SUPPORT BRACKETS AND DISCONNECT BRACKETS ON TREATED LUMBER
(PRESERVATIVE-TREATED). STAINLESS STEEL LAG SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UNTREATED
LUMBER.

INSTALLATION

NOTE: It is recommended that 5/16” x 2” lag screws will be pilot drilled using a 3/16” drill bit, prior to fastening.

7
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

1
Tools Needed:
Tape Measure
Hacksaw
Power Drill
5/16” Drill Bit

Cutting Vertical Track and
Installing Fully Adjustable Jamb
Brackets

Horizontal
track

NOTE: If you have riveted track, skip
this step.

12”
12”

Vertical track must be cut to the proper
length prior to installation.
IMPORTANT: Doors that are 7’-0”
or 8’-0” in height do not require
cutting the vertical track.
Determine the radius of your horizontal
track. Using this measurement, refer
to the vertical track cutting chart to
determine the length of the vertical
track. Cut the track off at the top.
Now, two holes must be drilled into the
top of the cut vertical track. Refer to the
illustration shown for hole locations.
Use a 5/16” drill bit.

Vertical Track Cutting Chart
Horizontal
Track Radius

Vertical Track Cut Length

10”, 12”

Door Height Minus 10”

14”

Door Height Minus 8”

3-1/2” LHR

Door Height Minus 15”

6-1/2” LHR

Door Height Minus 12”

1/2”

To attach the top jamb bracket, JB-3,
locate the third set of quick install
features of the vertical track. Align
the slot in the jamb bracket with the
slot above the quick install features in
the vertical track. The long side of the
bracket is placed against the track.
Fasten the jamb bracket finger tight,
using (1) 1/4”- 20 x 5/8” carriage bolt
and (1) 1/4”- 20 flange hex nut.
Repeat for other vertical track.

Vertical Track Cut Length

Cut vertical
track here

5/8”

Repeat for other vertical track.
To attach the bottom jamb bracket,
JB-2, locate the first set of quick install
features of the vertical track. Align
the slot in the jamb bracket with the
slot above the quick install features in
the vertical track. The long side of the
bracket is placed against the track.
Fasten the jamb bracket finger tight,
using (1) 1/4”- 20 x 5/8” carriage bolt
and (1) 1/4”- 20 flange hex nut.

Stamped
radius

5/16”

5/8”

fully adjustable
jamb bracket

3rd Set

jamb bracket

slot
(1) 1/4”- 20 x 5/8”
carriage bolt

(1) 1/4”-20
flange
hex nut

quick install
feature

vertical
track
1st Set

jamb bracket

quick install
feature

vertical
track

8
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

2
Tools Needed:
None

Attaching Fully Adjustable
Flagangle to Vertical Track

Fully Adjustable
flagangle

NOTE: If you have riveted track, skip this
step.
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 after
flagangle spacing is complete (Step 14).
(2) 1/4”- 20
flange hex
nuts

INSTALLATION

(2) 1/4”- 20 x 5/8”
carriage bolts

vertical
track

3
Tools Needed:
Power Drill
7/16” Socket
Driver
Torx Bit

Bottom Bracket

left hand
Bottom Bracket

NOTE: For door section identification see
page 4.
Align the center hole of bottom bracket
with hole #3 in the end stile of bottom
section. Fasten with (2) 1/4”-20 x 11/16”
self drilling screws and (1) 1/4”-20 x 5/8”
tamper-resistant self drilling screw as
shown.

(2) 1/4”-20 x 11/16”
self drilling
screws

Repeat for other side.
NOTE: All doors are provided with the
tamper resistant fastener for the bottom
brackets. However, the professional
installer is most likely to have the
proper tool to install this fastener. If the
homeowner does not have the proper tool
to install the tamper resistant fastener,
use a regular 1/4 – 20 x 7/8” self drilling
screw in its place.

#3 hole

(1) 1/4”- 20 x 5/8”
tamper-resistant
self drilling
screw

Bottom
Bracket
center hole

6
5
3

warning
label

4
2
1

end stile hole
pattern
(Left side is shown.
right side is
opposite.)

Bottom
Bracket

Bottom
section

9
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

4
Tools Needed:
None

Drums
IMPORTANT: Right and left hand is
always determined from inside the
garage looking out.

left hand
TORQUEMASTER® plus
counterbalance DRUM

NOTE: For door section identification see
page 4.
TorqueMaster® Plus counterbalance
drums are marked right and left hand.
Uncoil the counterbalance cables and
make sure you place the right hand
cable loop on the milford pin of the right
hand bottom corner bracket. Place the
left hand cable loop on the milford pin of
the left hand bottom corner bracket.

BOTTOM SECTION

Insert a roller into each bottom bracket
of the bottom section.
MILFORD PIN

NOTE: Verify astragal (bottom seal)
is aligned with door section. If there
is more than 1/2” excess astragal on
either side, trim astragal even with door
section.
counterbalance
cable

bottom
bracket

MILFORD PIN

roller
hinge tube

BOTTOM SECTION

astragal

10
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

5
Tools Needed:
Power Drill
7/16” Socket
Driver

Hinges
3

Position the lower (numbered) leaf of the
#1 end hinge over the #1 and #4 holes in
the top of the end stiles, and secure to the
end stiles by 1/4”-14 x 5/8” self tapping
screws. Position and secure #1 center
hinge(s) with 1/4”-14 x 5/8” self tapping
screws using the pre-punched holes in
the top of the center stile(s).

1
2
4
6

roller
placement

NOTE: The #1 hinges serve as end hinges
on the bottom section. The #1 hinges also
serve as center hinges at all center hinge
locations.

#1 Hinge

#2 End Hinge

Repeat for all other sections using the #2
end hinges on the second (lock section)
and the #3 end hinges on the third section
(intermediate section).
NOTE: #4 End hinges are used on fourth
section of five section doors.
IMPORTANT: When placing rollers
into end hinges #2 and higher, the
roller goes into the tube furthest
away from section.
IMPORTANT: once fastener are
snug against hinge leaf, tighten an
additional 1/4 to 1/2 turn to receive
maximum design holding power.

roller
placement
end stile hole
pattern
(Left side is shown.
right side is
opposite.)

center stile
hole pattern

roller
placement
#3 End Hinge

#4 End Hinge

hinge

#1 hole
#4 hole

(2) 1/4”-14 x 5/8”
self tapping
screws

end stile
end hinge placement

hinge

center stile

(2) 1/4”-14 x 5/8”
self tapping
screws

center hinge placement

11
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

INSTALLATION

Insert roller into appropriate hinge tubes.

6
Tools Needed:
Power Drill
7/16” Socket
Driver

Top Bracket
Align upper-center hole of top bracket
base with #6 hole in the end stile (See end
stile hole layout). Secure with
(1) 1/4”- 20 x 7/8” self drilling screw.
Ensuring top bracket is level and aligned
with edge of section. Permanently fasten
top bracket with (4) 1/4”- 20 x 7/8” self
drilling screws, one in each corner of the
top bracket base.
Remove the 1/4”- 20 x 7/8” self drilling
screw installed in the upper-center hole of
the top bracket base.

#6 hole

top bracket
base

end stile

(4) 1/4-20 x 7/8” self
drilling screw
(1) 1/4”- 20
flange hex
nut
top
bracket
slide

(1) 1/4”- 20 x 5/8”
carriage bolt

top
bracket
base

Loosely hand tighten top bracket slide
to base with (1) 1/4”- 20 x 5/8” carriage
bolts and (1) 1/4”- 20 flange hex nuts.
Insert roller and repeat for other side.

7
Tools Needed:
Pencil
Power Drill
5/16” Drill Bit
Phillips
Screwdriver

Locate the center most stile on the
bottom section of the door. Using the
pre-punched holes at the bottom of
the stile as a template, drill (2) 7/32”
dia. holes through the section. Using
the previously drilled holes as a guide,
enlarge the holes from outside the door
to 7/16” diameter. Assemble the outside
and inside step/lift plates to the section
using (2) #8 x 1-5/8” screws.
NOTE: Do not drill through or enlarge
holes on the inside of the door.

top section

top
bracket
assembly

NOTE: For doors with a glazed top section
(windows). Top strut may be mounted
between #2 and #6 holes before top
bracket is installed. See step 8 for U-Bar
installation.

Step Plate

top section

bottom
section

OUTSIDE
STEP PLATE

Step Plate Outside
bottom
section

bottom
section

NOTE: After completing this step,
continue with Step 8 on page 13.

inside step
plate

inside step
plate
(2) #8 x 1-5/8” self
tapping screws

Step Plate inside
12
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U-Bar

Tools Needed:

NOTE: For door section identification see
page 4.

7/16” Socket
Driver

Installation on the Top Section:
Doors 14’0” wide and over, locate U-Bar
above top bracket and secure with
(2) 1/4”-20 x 7/8” self drilling screws at
each end and center stile location.
NOTE: 3” U-Bars are now supplied with
all glazed doors starting at 14’0” width.

U-bar

(2) 1/4”- 20 x 7/8”
self drilling
screws

TOP
SECTION

installation on all other
Sections:

TOP
SECTION

NOTE: All U-Bars are placed at the top
of the section, against the bottom of the
hinges, for the intermediate, lock and
bottom sections.

side profile
door
section

NOTE: For doors 16’1” to 18’0” that
have a glazed intermediate section, the
U-bar needs to be placed on the glazed
intermediate section.

u-bar placement for top section
top section

Hinge

u-bar

U-Bar

NOTE: All 8200 series doors 14’0” to
16’0” wide, 6’0” to 7’0” high (4 section
high only) are now supplied with a 2” UBar for the top of the bottom section.

top
bracket
assembly

Place the U-Bar on the section against the
bottom of the hinges. Center the U-Bar
u-bar placement for bottom, lock and intermediate sections
side to side on the section at the location
Hinge
Hinge
shown, and secure to the section using
bottom section
U-Bar
(2) 1/4”-20 x 7/8” self drilling screws at
each end and center stile location.
U-Bar

8000 Series U-Bar Schedule
Door Width

4 Section

5 Section

8’-0” to 13’-11”

N/A

14’-0” to 16’-0”

(1) 2” U-Bar

16’-1” to 18’-0”

(3) 2” U-Bar

(2) 1/4”- 20 x 7/8”
Self Drilling
Screws

bottom
section

(2) 1/4”- 20 x 7/8”
Self Drilling
Screws

Model 46 U-Bar Schedule
Door Width

4 Section

8’-0” to 14’-11”

N/A

5 Section
N/A

15’-0” to 16’-0”

(1) 2” U-Bar

16’-1” to 18’-0”

(3) 2” U-Bar

attaching end stile

attaching center stile

13
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INSTALLATION

Power Drill

u-bar placement for top section

Lift Handle

Tools Needed:

NOTE: Doors with a Keyed lock do not require this lift
handle.

Tape Measure
Pencil
Power Drill
9/32” Drill Bit
1/2” Drill Bit
1/4” Wrench

Lock
Section

Lift
handle

NOTE: For door section identification see page 4.
Locate the inside center stile or the desired lift handle
location on the lock (2nd) section of the door. Position
the lower hole in the lift handle 4” from the bottom of
the second section.
IMPORTANT: The lift handle and the step/lift plate
need to be vertically aligned.

Lift
handle

(2) spacers
bottom
Section

(2) 1/4” x 2-1/2”
Carriage bolts

lift handle outside
Lock
Section

4”
MAX.

Vertically
aligned

Drill (2) 9/32” dia. holes through section. Enlarge the
holes from outside the door to 1/2” dia.

bottom
Section

Assemble the outside and inside lift handle to the
section using (2) 1/4” x 2-1/2” carriage bolts,
( 2) 1/4”- 20 hex nuts and (2) spacers.
NOTE: Do not drill through or enlarge holes on the
inside of the door.

Lift
handle

(2) 1/4”-20
Hex Nut

bottom Section

lift handle inside

10
Tools Needed:
Level

8” MAX.

Bottom Section
Center the bottom section in the door
opening. Level section using wooden
shims (if necessary) under the bottom
section.

jamb
header

weather
seal

level
jamb

Wooden Shims
(if necessary)

bottom
section

14
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Tools Needed:
3/16” Drill Bit
Power Drill
7/16” Socket
Driver
Tape Measure
Level
Step Ladder

Vertical Track

5/8”

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.

fLAGANGLE
5/16 x 2” hex
head LAG
SCREWS

Position the left hand vertical track assembly
over the rollers of the bottom section. Make
sure the counterbalance cable is located
between the rollers and the door jamb. Keep
track 5/8” from edge of door as shown in
illustration.

VERTICAL
TRACK
ASSEMBLY
BOTTOM SECTION

Drill 3/16” pilot holes for the lag screws.
Loosely fasten jamb brackets and flagangle to
the jamb using 5/16” x 2” lag screws.
On the bottom jamb bracket, tighten the lag
screw securing the bottom jamb bracket to
the jamb. Make sure the 5/8” track spacing is
maintained.

roller

flagangle hole
selection
jamb bracket

JAMB
BRACKET

INSTALLATION

vertical
track

Hang the cable drum over the flagangle.
Repeat for the right hand side.

12
Tools Needed:
Power Drill
7/16” Socket
Driver

5/16” x 2”
hex head
lag screw

Stacking Sections
NOTE: For door section identification see
page 4.
NOTE: Make sure hinges are flipped down,
when stacking another section on top.
Place rollers in hinge tubes of the second
section (lock section).
With assistance, lift the second section and
guide rollers into the vertical tracks.

lock section

Repeat for other section(s) except top
section.
Attach center hinge leaves to sections using
1/4”-14 x 5/8” self tapping screws. Repeat
for the upper hinge leaves.
IMPORTANT: Push & hold the hinge
leaves against section while securing
hinges.
NOTE: Install lock at this time (sold
separately). See instructions in OPTIONAL
SIDE LOCK INSTALLATION on page 32.

15
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Top Section

Tools Needed:

Place the top section in the opening and
vertically align with lower sections.

Hammer
Nail
Power Drill
7/16” Socket
Driver
7/16” Wrench

door width
+3-3/8” to 3-1/2”

NAIL

Temporarily secure the top section by
driving a nail in the header near the
center of the door and bending it over
the top section.
Now flip up the hinge leaf against
section, fastening center hinge(s) first
and end hinges last.

Tape Measure

14
Tools Needed:
Power Drill
7/16” Socket
Driver
Tape Measure

Vertical Track Alignment
When installing a door with a
TorqueMaster® Plus counterbalance
system, vertical track alignment is
critical. Position flagangle between
1-11/16” (43 mm) to 1-3/4” (44 mm)
from the edge of the door. Tighten the
bottom lag screw. Flagangles must be
parallel to the door sections. Repeat for
opposite side.
IMPORTANT: THE DIMENSION BETWEEN
THE FLAGANGLES MUST BE DOOR WIDTH
PLUS 3-3/8” (86 MM) TO 3-1/2” (89 MM)
FOR SMOOTH, SAFE DOOR OPERATION.
Complete the vertical track installation
by securing the center jamb bracket(s)
and tightening the other lag screws. Push
the vertical track against the rollers so
that the rollers are touching the deepest
part of the curved side of the track (see
illustration). Tighten all the carriage bolts
and nuts. Repeat for opposite side.

FLAGANGLE

1-11/16” TO 1-3/4”

vertical track
ROLLER

top section

ROLLER Against
VERTICAL TRACK

16
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Tools Needed:
9/16” Socket
7/16” Socket
Ratchet Wrench
9/16” Wrench
Level
Hammer
Step Ladder

Horizontal Track
To install horizontal track, place the curved end over the
top roller. Align the bottom of the horizontal track with
the vertical track. Hand tighten the horizontal track to
the flagangle with (2) 1/4”-20 x 5/8” carriage bolts and
(2) 1/4”-20 flange hex nuts.

(2) 1/4”- 20 x 5/8”
carriage bolts

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 nut. Repeat for other
side.

(2) 1/4”-20 flange
hex nuts

Tighten the remaining carriage bolts and nuts to complete
the horizontal track installation.

flagangle

Horizontal
angle

WARNING

DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS
ARE SECURED AT REAR, AS OUTLINED IN STEP
27, OR DOOR COULD FALL FROM OVERHEAD
POSITION CAUSING SEVERE OR FATAL INJURY.

flagangle

INSTALLATION

Remove the nail that was temporarily holding the top section
in place, installed in Step 13.
IMPORTANT: Failure to remove nail before
attempting to raise door could cause permanent
damage to top section.

(1) 3/8”-16
hex nut

NOTE: If an idrive® opener will be installed, position
horizontal tracks slightly above level.

16
Tools Needed:
7/16” Wrench
Step Ladder

Adjusting Top Brackets
With horizontal tracks installed you can
adjust the top brackets.
Vertically align the top section with the
lower sections. Once aligned, position
the top roller in the top bracket slide out
against the horizontal track. Maintaining
the slide’s position, tighten 1/4”- 20
flange hex nut to secure the top bracket
slide to the top bracket base.

(1) 3/8-16 x 3/4”
hex head bolt

HORIZONTAL
track
top
section

Correct

Repeat for other side.

TOP ROLLER
TOP BRACKET
SLIDE

top
section

top
section
incorrect
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17
Tools Needed:
None

TorqueMaster® Spring Tube
TorqueMaster® springs come lubricated
and pre-assembled inside the
TorqueMaster® spring tube. To install, lay
the TorqueMaster® spring tube on the
floor (inside garage) in front of the door
with the labeled end to the left.
IMPORTANT: Right and left hand is
always determined from inside the
garage looking out.

TorqueMaster®
Spring Tube

LABELED END

18
Tools Needed:
None

Center Bracket Bushing
CENTER
BRACKET
ASSEMBLY

idrive®

NOTE: If you are installing the
opener with your garage door, skip this
step and go to your idrive® Installation
Instructions and Owner’s Manual. After
completing steps 1-13 of your idrive®
Installation Instructions and Owner’s
Manual, rear supports will need to be
fabricated/installed to support both
horizontal tracks, see step 27.
NOTE: If you are not installing the
idrive® opener on your garage door, you
must install the center bracket bushing
assembly. Follow these instructions for
non-idrive® operated garage doors.
Being cam shaped, the center bracket
bushing only fits one way.
Slide the center bracket assembly
towards the center of the TorqueMaster®
spring tube, from the right side as
shown.

TorqueMaster®
Spring Tube

CENTER
BRACKET
BUSHING

18
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19
Tools Needed:
None

Drum Wraps
IMPORTANT: RIGHT AND LEFT HAND
IS ALWAYS DETERMINED FROM INSIDE
THE GARAGE LOOKING OUT.

Right Hand Drum Wrap

Drum wraps are identified as right and
left.
Slide the left hand drum wrap over the
left side of the TorqueMaster® spring
tube assembly with the tabs facing
left. Continue sliding the left hand
drum wrap towards the center of the
TorqueMaster® spring tube assembly.

Left Hand Drum Wrap

INSTALLATION

Slide the right hand drum wrap over the
right side of the TorqueMaster® spring
tube assembly with the tabs facing
right. Continue sliding the right hand
drum wrap towards the center of the
TorqueMaster® spring tube assembly.

Left Hand
Drum Wrap

TorqueMaster®
Spring Tube Assembly

Tabs

19
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20
Tools Needed:
Tape Measure

TorqueMaster®
Spring Tube Assembly

Cable Drums
IMPORTANT: RIGHT AND LEFT HAND
IS ALWAYS DETERMINED FROM INSIDE
THE GARAGE LOOKING OUT.

Winding
Shaft

Shake the TorqueMaster® spring tube
assembly gently to extend the winding
shafts out about 5" on each side. For
single spring applications, there will be
no left hand spring in the
TorqueMaster® spring tube assembly.
L ift the TorqueMaster® spring tube
assembly and rest it on the top of the
flagangles.
NOTE: Cable drums are marked right
and left hand. Cable drums and
TorqueMaster® spring tube assembly
are cam shaped to fit together only one
way.

5”

TorqueMaster® Spring Tube
Assembly

Right Drum

Counterbalance Cable

1/2 Wrap Shown
TorqueMaster® Spring Tube
Assembly

Right Drum

Counterbalance Cable

Pre-wrap the TorqueMaster® plus cable
drum with the counter balance cable
with 1/2 or 1-1/2 wraps (see
illustration)
1-1/2 Wrap Shown

To install the cable drum, slide the
correct cable drum over the winding
shaft until the cable drum seats against
the TorqueMaster® spring tube
assembly.

Splines
Groove
Winding shaft

The winding shaft must extend past the
cable drum far enough to expose the
splines and the groove. Align the
winding shaft groove with the round
notch in the flagangle.

Cable
Drum

Round Notch
Flagangle

For double spring applications:
Repeat for opposite side.
For single spring 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 in handling the loose winding
shaft (left side) so that it does not slide
back into the TorqueMaster® spring
tube assembly.

Counterbalance Cable
Winding shaft
Cable
Drum
Groove
Splines

Use
this these
lab Illustr
el.
ati

on,

WA
RN

in co
nju

nctio

Please Do Not Return This Product To The Store. Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your
local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Rac
n wi
th
he
EX t Bra the Ins
tru
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cket
ction
ENE
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s on
To
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oth
VIER
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er
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un s fromO N seve
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g( he m
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21
Tools Needed:
Power Drill
7/16” Socket
Driver
1/2” Wrench

Splines

End Brackets

Groove

IMPORTANT: Warning Tags must be
securely attached to both End
Brackets.
End brackets are right and left hand.
You can identify the right hand end
bracket by the disconnect cable guide
hole in the top of the bracket.

Disconnect
Cable Guide
Hole
Winding
Shaft

Warning
Tag

Step Ladder
Beginning with either side, slide the end
bracket onto the winding shaft so that
the grooves in the ratchet wheel fit onto
the winding shaft splines.

Use
this these
lab Illustr
el.
ation

WA
R

, in

conju

NIN

tion
Rac
with
he
EX t Bra the Ins
tru
TR
ction
ENG
EAGMcket
s on
To
is un
EDE
the
fataavoidTENSSIDSE P
oth
VIER
de
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er sid
fast l inju poss ION ING r
e of
en ry,
ib .
er
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OT re
rin ratche rem or
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g(s)
ov
AG
w
t
sa
ED
fely nwou are brac e
UN
DE
RN
an
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d EAT
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win .
fo
inst llo W re d
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re
DO
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Cab
T R man ctcheiot Paw
le Dru
in
EM ual. nsl /o the
m
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spa
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rs
Rat ce bet
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t Paw n
IS No space
Cab
l
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le Dru and
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m
indi .

Right End
Bracket

DIS

che
cate Cable
s eng Drum t
age
me
nt

ENG

SID

E VIE
W

DIS

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TH

VIE

Rat

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ITIO
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POS

wee
and n Rat
che
Cab
-ind
le Dru t Paw
icat
l
es eng m
age
me
nt

non

LOW

Right End
Bracket

INSTALLATION

Secure end bracket to the jamb using
(1) 5/16” x 2” hex head lag screw and
(1) 5/16”-18 x 3/4” carriage bolt and
5/16” hex nut.

ENG

POS
ITIO

Rat

che

t Paw

l in

Upp

er Pos

ition

UPP

POS

Rat

che

t Paw

ITIO
N SID
E VIE
W

l in

Low

er Pos

ition

LOW

POS

ITIO

N SID

E VIE

NOTE: Install carriage bolt and hex nut
first then apply lag into header.
Repeat for other end bracket.
Use
this these
lab Illustr
el.
at

WA
R

ion

Ratchet
Wheel
Teeth
Pointing
Upward

, in

conju

nctio

NIN

Ra
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th
EX et Bra the Instr
TR
uctio
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ns
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on
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the
nd
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inst llo W re d
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5/16” x 2”
Hex Head Lag

Use
thes
this
e
labe Illustrati
l.
on,

5/16”-18 x 3/4”
CARRIAGE Bolt

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WA
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GAGE
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R POSIT
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betwe
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and
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non-in Cable
dicate Drum
s engag
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R POSIT
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et Pawl

in Upper

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Ratch

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R POSIT

ION

SIDE

in Lower

VIEW
LOWE
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Positio
n

VIEW

21
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

22
Tools Needed:
Power Drill
3/16” Drill Bit
7/16” Socket
Driver
Step Ladder

Securing Center Bracket Bushing
NOTE: If you are not installing the
idrive® opener on your garage door, you
must install the center bracket bushing
assembly, follow these instructions.

CENTER
BRACKET
ASSEMBLY

To locate the center bracket, mark the
header halfway between the flagangles
and level the TorqueMaster® spring
tube. Drill 3/16” pilot holes into header
for the lag screws. Fasten the metal
bracket to the header using
(2) 5/16” x 2” lag screws.

(2) 5/16” x 2” hex
head lag screws

22
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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

23
Tools Needed:
(2) Vice Clamps

Securing Door
for Spring Winding
P lace vice clamps onto both vertical
tracks just above the third roller. This is
to prevent the garage door from raising
while winding counterbalance spring(s).

WARNING

Failure to place vice clamps
onto vertical Track can
allow door to raise and
cause severe or fatal
injury.

INSTALLATION

place vice
clamps above
3rd Roller

vice clamps
attached to
inner rail
of track

Track

23
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24
Tools Needed:
Pliers
Flat Tip
Screwdriver
Step Ladder

Cable Adjustment
Starting on the right hand side, rotate
the cable drum until the set screw
faces directly away from the header.
Torque tube cam peak should be
pointing straight up. Loosen the set
screw no more than 1/2 turn. Using
locking pliers, pull on the end of the
cable to remove all cable slack.
IMPORTANT: a MINIMUM of a 1/2
wrap IS REQUIRED FOR PROPER DOOR
OPERATION. Cable must be taut and
in the first groove of the cable
drum.
Check to ensure the cable is aligned
and seated in the first groove of the
cable 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
TO WINDING SPRINGS.

1/2 wrap Shown

First
groove

Cam peak
Set
screw
Set Screw
1-1/2 wrap Shown

Right hand drum
First
groove

Cam peak
Set screw

Right hand drum

Cable drum hole
Cut cable here

6”
Pliers

Leave approximately 6” of cable and cut
off the rest. Insert excess cable into hole
of cable drum.
NOTE: Illustrations show the right hand
TorqueMaster® Plus drum, left hand
TorqueMaster® Plus drum is
symmetrically opposite.

Use these Illustration, in con
this label.

Rach
EXT

To avoi
fatal inju
fastener
until

To safe

ENGAGED UNDERNEATH VI

and follo
installatio

DO NOT

No space
Ratchet
Cable

DISENGAGED UNDERNEATH

No space
Ratchet

Cable

UPPER POSITION

Ratchet Pawl in Upper P

UPPER POSITION SIDE VIEW

24
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Tools Needed:
Ratchet Wrench
5/8” Socket
3” Extension
Gloves

WARNING

it is recommended that
leather gloves be worn while
winding the TorqueMaster®
Plus springs. Failure to wear
gloves may cause injury to
hands.
Double check to ensure the
counterbalance cable is aligned in the first
groove of the cable drum as shown in Step
24.

Door Height

Spring Turns

Door Height

Spring Turns

6’-0”

7’-0”

6’-3”

14-1/2

7’-3”

16-1/2

6’-5”

7’-6”

6’-6”

7’-9”

17-1/2

6’-8”

15-1/2

8’-0”

6’-9”

15-1/2

WARNING

End Bracket

Prior to winding or making
adjustments to the springs,
ensure you’re winding in the
proper direction as stated in
the Installation Instructions.
Otherwise, the spring fittings
may release from spring
if not wound in the proper
direction and could result in
severe or fatal injury.

Marks

Ratchet

5/8” Socket

Starting with the right hand side, place a
mark on winding shaft (or socket) and end
bracket. Turn the pawl knob on the end
bracket to the upper position.
IMPORTANT: Using a ratchet with a 5/8”
(16 mm) socket (NOTE: A 3” (76 mm)
extension is recommended for added
clearance from the horizontal angle), wind
the spring by rotating the winding shaft
counter clockwise, while watching the
mark on the winding shaft.
IMPORTANT: pawl knob must be
in upper position to add/remove
required number of spring turns.
After 2-3 turns, remove the ratchet and
adjust the cable tension on the left side.
Ensure the cable is in the first groove of
the cable drums, as shown in Step 24.
NOTE: Single spring applications require
no spring winding 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 number of turns:

INSTALLATION

RECOMMENDED SPRING TURNS

Winding Springs

3”
Extension

End Bracket

Pawl Knob in Upper
Position

For single spring applications:
Return to the right hand and continue
winding the spring to the required number
of turns for your door. Place pawl knob in
lower position.
For double spring applications:
Place a mark on the winding shaft and end
bracket. Place the ratchet with 5/8” socket
25
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Winding Springs Continued...
Tools Needed:

onto the left hand winding shaft end. To
wind the spring, rotate the winding shaft
clockwise, while watching the mark on the
winding shaft.
Rotate the winding shaft to the required
number of turns for your door. Then return
to the right hand side and wind the right
hand spring to the required number of
turns. Place pawl knob in lower position on
both sides.
IMPORTANT: Mark Number of Spring
Turns on TorqueMaster® Plus end
bracket warning tag.
NOTE: Since total turns to balance door
can deviate from spring turn chart
values by ± 1/2 turn, adjustments to the
recommended number of turns may be
required after the rear hanger assembly
is completed.
IMPORTANT: Hold the door down to
prevent it from raising
unexpectedly, in the event the
spring was overwound and
cautiously remove vice clamps from
vertical tracks.
Do not raise the door until horizontal
tracks are secured at the rear, as outlined
in step 27.

End Bracket

Pawl Knob in Lower
Position
Back of torquemaster® plus end bracket warning tag

Spring Turns
Door Height

WARNING
Raising door further can
result in door falling and
cause severe or fatal injury.

26
None

Spring Turns

(6’ - 0”)

(6’ - 3”)

14 - 1/2

(6’ - 5”)

(6’ - 6”)

(6’ - 8”)

15 - 1/2

(6’ - 9”)

15 - 1/2

(7’ - 0”)

(7’ - 3”)

16 - 1/2

(7’ - 6”)

(7’ - 9”)

17 - 1/2

(8’ - 0”)

Location for
marking number
of installed
spring turns

Number of Installed Spring Turns

Drum Wrap Installation
Starting with the left hand side, align
the counterbalance cable with one of
the slots in the drum wrap. Slide the
drum wrap over the drum until the tabs
snap between the cable drum and the
ratchet gear. Repeat for right hand side.

drum
(left hand)

Counterbalance cable

tabs

groove
in drum

26
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Tools Needed:
Ratchet Wrench
1/2” Socket
1/2” Wrench
(2) Vice Clamps
Tape Measure
Level
Hammer
Step Ladder

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 horizontal track is not yet
supported.

WARNING

Raising door further can
result in door falling and
cause severe or fatal injury.

Clamp a pair of vice clamps on the vertical
tracks just above the second roller on one
side, just below the second roller on the
other side. This will prevent the door from
raising or lowering while installing the rear
support.
Using perforated angle, 5/16” x 1-5/8”
hex head lag screws and 5/16” bolts
with nuts (may not be supplied), fabricate
rear support for horizontal tracks. Attach
horizontal tracks to the rear supports with
5/16”-18 x 1-1/4” hex bolts and nuts (may
not be supplied). Horizontal tracks must be
level and parallel within 3/4” maximum of
door edge.

vice
clamps

vertical
TRACK

WARNING
Keep horizontal 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 HANGER THAT
CANTILEVERS 4” OR MORE BEYOND A
SOUND FRAMING MEMBER.

NOTE: If rear supports are to be installed over
drywall, use 5/16” x 2” hex head lag screws.
NOTE: If an idrive® opener is installed, position
horizontal tracks one hole above level when
securing it to rear supports.
NOTE: Perforated ceiling angle must be
attached to sound framing members with lag
screws. Nails should not be used. Permanently
attach the weather seal to both door jambs and
header. (Temporarily attached in PREPARING
THE OPENING on page 6.) Avoid pushing
weather seal too tightly against face of door.

3/4”

3/4”
Door Edges
Horizontal Tracks

TOP SECTION

WARNING
Prior to winding or making
adjustments to the springs,
ensure you’re winding in the
proper direction as stated in
the Installation Instructions.
Otherwise, the spring fittings
may release from spring
if not wound in the proper
direction and could result in
severe or fatal injury.

Horizontal
Tracks
27

INSTALLATION

DOOR IN THE
UP POSITION

Rear Support

Rear Support Continued...
Tools Needed:

Now, lift door and check it’s balance. Adjust, if

Sound Framing Members

door lifts by itself (hard to pull down) or if
door is difficult to lift (easy to pull down).
Anytime spring adjustments are made,
ratchet pawl knob must be in the upper
X. PERFORATED CEILING
position to add/remove required number
MA
ANGLE - BOLTED USING (2)
”
4
PERFORATED
of spring turns. To adjust springs, only add
2
5/16” X 1-5/8” HEX HEAD
CEILING ANGLE
or remove a maximum of 3/10 of a turn
LAG SCREWS TO CEILING
MEMBER AND PARALLEL
(three teeth of ratchet wheel) at a time.
TO WIDTH OF DOOR. SPACE
Both sides need to be adjusted equally on
LAG SCREWS NO FURTHER
double spring doors.
THAN 24” APART
Add Spring Tension: The ratchet wheel is
made of 10 teeth. To add spring tension,
HORIZONTAL TRACK
BOLT MUST EXTEND INTO
ensure the ratchet and socket is set so
THE TRACK TO SERVE AS
that it will tighten counter clockwise on
A ROLLER STOP
the right hand side, and clockwise on the
left hand side. Place the ratchet with 5/8’
Sound Framing Members
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 pawl,
creating three “clicks”.
Remove Spring Tension: To remove
X. PERFORATED ceiling ANGLE
MA - BOLTED USING (2) 5/16” X
”
spring tension, ensure the ratchet and
24
1-5/8” HEX HEAD LAG SCREWS
PERFORATED
socket is set so that it will tighten counter
TO CEILING MEMBERS AND
ceiling ANGLE
clockwise on the right hand side and
PARALLEL TO WIDTH OF DOOR.
clockwise on the left hand side. It is
ATTACH VERTICAL PERFORATED
recommended that a regular 5/8” wrench
CEILING ANGLE BETWEEN THE
(2) 5/16” X 1-5/8” HEX HEAD
be used. Place the wrench onto the
LAG SCREWS, SECURING
winding shaft. Pull down on the wrench
PERFORATED CEILING ANGLE
HORIZONTAL TRACK
to relieve pressure between the pawl and
TO CEILING MEMBERS
the ratchet wheel. Push in on the pawl to
BOLT MUST EXTEND INTO
allow the three ratchet wheel teeth to pass
THE TRACK TO SERVE AS
by the pawl, as you carefully allow the
A ROLLER STOP
wrench to be rotated upward by the spring
PERFORATED ceiling
tension. Release the pawl to allow it to
ANGLE
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 turn from
specified amount. If the door still
does not operate easily, lower
the door into the closed position,
UNWIND SPRING(S) TO ZERO, and
jamb 1/8” to 1/4”
recheck the following items:
(3) 5/16”
1.) Check the door for level.
BOLTS & NUTS
2.) Check the TorqueMaster® spring tube
permanently attached
and flagangles for level and plumb.
weather seal
3.) Check the distance between the
flagangles - must be door width plus
3-3/8” to 3-1/2”.
4.) Check the counterbalance cables
for equal tension - adjust if necessary.
5.) Rewind the spring(s).
6.) Make sure door isn’t rubbing on
jambs.
NOTE: If an idrive was installed and
you have completed your rear support
installation, refer to the idrive Installation
Instructions and Owner’s Manual to
complete your idrive installation.

28
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Tools Needed:
5/8” Socket
Ratchet Wrench
3” Extension
Vice Clamps
(Pair)

WARNING
READ THESE INSTRUCTIONS
CAREFULLY BEFORE
ATTEMPTING TO RESET THE
TORQUEMASTER® plus SYSTEM.
IF IN QUESTION ABOUT ANY
OF THE PROCEDURES, DO NOT
PERFORM THE WORK. INSTEAD,
HAVE A TRAINED DOOR SYSTEMS
TECHNICIAN RESET THE SYSTEM.
This door is equipped with a
TorqueMaster® Plus system, which
provides a safety feature that prevents
the door from rapidly descending in
case of spring failure or forceful manual
operation. Typical sign of an engaged
system: Door opens, but will not close;
door makes a distinct “clicking” noise
upon opening. If the system is engaged,
carefully follow the reset instructions
below or refer to the door’s Installation
Instructions and Owner’s Manual to
reset the TorqueMaster® Plus system.
Resetting the anti-drop device
1. First, locate and visual inspect the
TorqueMaster® Plus end brackets to
determine if the system has engaged
(see illustration).

Ratchet
Pawl

Cable Drum

drum Pawl
ENGAGEMENT Underneath View

No space between
drum Pawl and Cable
Drum
indicates engagement

INSTALLATION

�

ENGAGEMENT SIDE VIEW

TorqueMaster® Plus Reset
Instructions

No space between
drum Pawl and
Cable Drum
NON-ENGAGEMENT SIDE VIEW

NOTE: If the TorqueMaster® Plus system
has not engaged, do not complete the
following step.
If the system has engaged, follow these
steps to reset the system:
Cable Drum

2. Disengage opener (if installed) by
pulling or placing emergency disconnect
in the manual operated position.
3. With the door in the open or partially
open position, clamp vice grips on both
vertical tracks just below the bottom
section roller.

drum Pawl

NON-ENGAGEMENT Underneath View

Space between DRUM Pawl
and Cable Drum
non-indicates engagement

4. Now is a good time to remove
vehicles or items from garage to provide
clear access to end brackets.
5. Flip the ratchet pawl knob on both
end brackets to the upper position (see
illustration).

Space between
drum Pawl and
Cable Drum

29
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TorqueMaster® Plus Reset
Instructions Continued...
Tools Needed:

6. Raise door 2”-3” and then lower
door. Repeat process until anti-drop
device resets (see disengaged system
illustration on previous page).
IMPORTANT: BE PREPARED TO SUPPORT
THE TOTAL WEIGHT OF THE DOOR.
place vice clamps
BELOW BOTTOM SECTION
on both vertical track

7. Cautiously remove the vice clamps
from the vertical tracks. With assistance,
lower the door.
8. Check for spring tension. Starting on
the right hand side, place a ratchet and
5/8” socket on the TorqueMaster® Plus
winding shaft (see illustration). Ensure
ratchet is set so that it will tighten
counter clockwise on the right hand 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 spring
tension is present, contact a qualified
door systems technician to replace the
spring(s).

UPPER Position

Lower Position

WARNING

TO AVOID POSSIBLE INJURY, HAVE A
TRAINED DOOR SYSTEM TECHNICIAN
MAKE ADJUSTMENTS/REPAIRS TO
CABLES, SPRING ASSEMBLIES AND
OTHER HARDWARE.
BALANCING DOOR
Lift door and check its balance. Adjust
spring(s), if door lifts by itself (hard to pull
down) or if door is difficult to lift (easy to
pull down). Anytime spring adjustments
are made, ratchet pawl knob must be in
the upper position (see illustration).
An unbalanced door such as this can
cause idrive® or TorqueMaster® Plus
operation problems. To adjust spring(s),
only add or remove a maximum of 3/10
of a turn (three teeth of ratchet wheel) at
a time. Both sides need to be adjusted
equally on double spring doors.

Pawl knob in UPPER
Position

Pawl Knob in Lower
Position

End Bracket

Ratchet
with 5/8”
Socket

NOTE: Single spring applications require
no spring winding on left hand side.
Clamp a pair of vice clamps on the
vertical tracks just above the second
roller on one side and just below the

PAWL
3” Extension

30
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TorqueMaster® Plus Reset
Instructions Continued...
second roller on the other side. This
will prevent the door from raising or
lowering while adjusting the spring(s).

place vice clamps
above 3rd Roller on
both vertical tracks

To Add Spring Tension:
The ratchet wheel is made of 10 teeth.
To add spring tension, ensure the
ratchet and socket is set so that it will
tighten counter clockwise on the right
hand side, and clockwise on the left
hand side. 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 Tension:
To remove spring tension, ensure the
ratchet and socket is set so that it will
tighten counter clockwise on the right
hand side and clockwise on the left
hand side. It is recommended that a
regular 5/8” wrench be used. Place
the wrench onto the winding shaft.
Pull down on the wrench to relieve
pressure between the ratchet pawl
and the ratchet wheel. Push in on the
pawl to allow the three ratchet wheel
teeth to pass by the ratchet pawl, as
you carefully allow the wrench to be
rotated upward by the spring tension.
Release the pawl to allow ratchet pawl
to engage with the ratchet wheel.
Remove the vice clamps from the
vertical tracks, re-check doors balance
and adjust if necessary. When door is
balanced and adjusted properly, place
the ratchet pawl knobs in the active
position (lower position).

vice clamps
attached to
inner rail
of track

Track

INSTALLATION

Tools Needed:

UPPER Position

Lower Position

Pawl knob in Lower
Position

Pawl knob in upper
Position

End Bracket

Ratchet
with 5/8”
Socket

PAWL
3” Extension

31
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�
Tools Needed:
Power Drill
7/16” Socket
Driver
Tape Measure

Side Lock
Install the side lock on the second
section of the door. Secure the lock to
the section with (4) 1/4”- 20 x 11/16”
self drilling screws. Square the lock
assembly with the door section and
align with the 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
operator is installed on the
door.
NOTE: After completing this step,
continue with Step 13 on page 16.

(4) 1/4”- 20 x 11/16”
self drilling screws

1/8”

32
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�
Tools Needed:
Pencil
1/4” Wrench
5/16” Drill Bit
Power Drill

Step Plate

bottom
section

NOTE: For alternative step/lift plate
installation, see “Step Plate” in the
optional installations on page 33.

step plate
bottom
section

Locate the center stile on the bottom
section of the door.
On the outside of the door, position step
plate directly above astragal retainer.
Using the step plate as a template,
mark hole locations for mounting on
door face.

step plate
assembly
(2) 1/4”-20 flange Hex nut
Inside step plate installation
bottom
section

Drill (2) 5/16” dia. holes through the
door face and insulation, if necessary, at
marked locations, being careful to keep
drill straight.
Mount step plates back to back,
straddling stile. Secure with
(2) 1/4 x 2-3/4” carriage bolts and
1/4”-20 flange hex nuts.

step plate

bottom section

step plate assembly
(2) 1/4 x 2-3/4”
carriage bolts
outside step plate installation

Tools Needed:
Power Drill
1/8” Drill Bit

NO. 6 SCREW EYE

optional INSTALLATION

�

Pull Rope

WARNING

DO NOT INSTALL PULL ROPES
ON DOORS WITH ELECTRIC
OPERATORS. CHILDREN MAY
BECOME ENTANGLED IN THE
ROPE CAUSING SEVERE OR
FATAL INJURY.
Measure and mark the jamb
approximately 48” to 50” (1220 to 1270
mm) from floor on the right or left side
of door. Drill 1/8” pilot hole for No. 6
screw eye. Tie the pull rope to the No.
6 screw eye and to the bottom bracket
as shown.

PULL ROPE
PULL ROPE
BOTTOM
BRACKET

33
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�

Trolley Operator

WARNING

Tools Needed:

OPERATOR MUST BE TESTED
AT TIME OF INSTALLATION AND
MONTHLY THEREAFTER AS
DESCRIBED IN YOUR
INSTALLATION INSTRUCTIONS
AND OWNER’S MANUAL, TO
ENSURE THAT DOOR SAFETY
FEATURES FUNCTION. FAILURE
TO TEST OR MAKE ANY
NECESSARY ADJUSTMENTS OR
REPAIRS, CAN RESULT IN SEVERE
OR FATAL INJURY.

OPERATOR RAIL
SUITABLE MOUNTING
SURFACE 2 X 6
LUMBER MINIMUM

DOOR ARM TO
OPERATOR BRACKET
HEADER

OPERATOR
rail
perforated
angle

1. Install operator rail 1/2” to 1-1/2”
(13 - 38 mm) above 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
slope down towards rear).

OPERATOR

FRAMING MEMBERS

3. Attach operator rail to suitable
mounting surface, 2 x 6 lumber
minimum.
4. Attach operator to ceiling using
perforated angle.

PERFORATED ANGLE

IMPORTANT: Angles must be
securely attached to sound
framing member(s).

34
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�

Cleaning

Cleaning Your Garage Door
IMPORTANT: DO NOT USE A PRESSURE WASHER ON YOUR GARAGE DOOR!
While factory-applied finishes on garage doors are durable, it is desirable to clean them on a routine basis. Some discoloration of the
finish may occur when a door has been exposed to dirt-laden atmosphere for a period of time. Slight chalking may also occur as a
result of direct exposure to sunlight.
Cleaning the door will generally restore the appearance of the finish. To maintain an aesthetically pleasing finish of the garage door, a
periodic washing of the garage door is recommended.
The following cleaning solution is recommended
A mild detergent solution consisting of one cup detergent (with less than 0.5% phosphate) dissolved into five gallons of warm water will
aid in the removal of most dirt.
NOTE: The use of detergents containing greater than 0.5% phosphate is not recommended for use in general cleaning of garage doors.
NOTE: Be sure to clean behind weather stripping on both sides and top of door.
CAUTION: NEVER MIX CLEANSERS OR DETERGENTS WITH BLEACH.
GLASS CLEANING INSTRUCTIONS
Clean with a mild detergent solution (same as above) and a soft cloth. After cleaning, rinse thoroughly.
ACRYLIC CLEANING INSTRUCTIONS
Clean acrylic glazing with nonabrasive soap or detergent and plenty of water. Use your bare hands to feel and dislodge any caked on
particles. A soft, grit-free cloth, sponge or chamois may be used to wipe the surface. Do not use hard or rough cloths that will 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.

�

Painting

Surface Preparation for Painting
Wax on the surface must be removed or paint peeling/flaking will result. To remove this wax, it will be necessary to lightly scuff the
surface with a fine steel wool pad, saturated with soapy water. A final wipe and rinse should be done with clean water only, to remove
any loose particles and any soapy film residue.
Surface scratches, which have not exposed the metal substrate, can be lightly buffed or sanded with 0000 steel wool or No. 400 sand
paper to create a smoother surface. Care must be taken to not expose the substrate under the paint. Once the substrate is exposed, the
likelihood for rusting is greatly increased.

Painting
After surface has been properly prepared, it must be allowed to dry thoroughly, and then coated immediately with premium quality latex
house paint. Follow paint label directions explicitly. Oil base or solvent base paints are not recommended. Please note that if substrate is
exposed and not properly primed, painting with latex paint may cause accelerated rusting of the steel in the exposed area.
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 doubt about any of the above directions.
3. Follow directions explicitly on the paint container labels for proper applications of coatings and disposal of containers. Pay particular
attention to acceptable weather and temperature conditions in which to paint.
35
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maintenance

If substrate is exposed, it must be treated to prevent rust from forming. Sand the exposed area lightly and paint with a high quality metal
primer, specifically intended for galvanized surfaces, to protect the area from corrosion. Allow for drying time on primer can label before
applying topcoat. The surface of the factory-applied finish, that is being painted, must not be too smooth, or the paint will not adhere to
it. It is advisable to test in an inconspicuous area, to evaluate adhesion. If poor adhesion is observed, surface preparation for painting the
factory-applied finish must be repeated until desired results are achieved. Again, care must be taken to not expose the substrate under
the paint.

Limited Warranty
Models 8000, 8100, 8200 and 46
Subject to the terms and conditions contained in this Limited Warranty, Wayne-Dalton Corp. (“Manufacturer”) warrants the sections of the door, which
is described at the top of this page, for a period of TEN (10) YEARS from the date of installation against:
(i)

The door becoming inoperable due to rust-through of the steel skin from the core of the door section, due to cracking, splitting, or other
deterioration of the steel skin, or due to structural failure caused by separation or degradation of the foam insulation.

Peeling of the original paint on the door as a result of a defect in the original paint or in the application of the original paint coating, in cases where
the door sections and the original paint: (a) have not been subjected to adverse atmospheric conditions or contaminates (such as salt water or
other marine environment, or to toxic or abrasive substances, including those in the air); (b) have been maintained in compliance
with Manufacturer’s recommendations; and (c) have not been subject to physical abrasion, impacted by a hard object, or punctured (including
without limitation “paint rub” occurring in metal to metal contact and movement).

(ii)

The Manufacturer warrants the garage door hardware (except springs) and the tracks of the above-described door, for a period of TEN (10) YEARS
from the date of installation, against defects in material and workmanship, subject to all the terms and conditions below.
The Manufacturer warrants those component parts of the door not covered by the preceding provisions of this Limited Warranty against defects in
material and workmanship for a period of ONE (1) YEAR from the date of installation.
This Limited Warranty is extended only to the person who purchased the product and continues to own the premises (where the door is installed) as
his/her primary residence (“Buyer”). This Limited Warranty does not apply to residences other than primary, or to commercial or industrial installations, or
to installations on rental property (even when used by a tenant as a residence). This Limited Warranty is not transferable to any other person (even when the
premises is sold), nor does it extend benefits to any other person. As a result this warranty does not apply to any person who purchases the product from
someone other than an authorized Wayne-Dalton dealer or distributor.
The Manufacturer will not be responsible for any damage attributable to improper storage, improper installation, or any alteration of the door or its
components, abuse, damage from corrosive fumes or substances, salt spray or saltwater air, fire, Acts of God, failure to properly maintain the door, or attempt
to use the door, its components or related products for other than its intended purpose and its customary usage. This Limited Warranty does not cover ordinary
wear. This Limited Warranty will be voided if the original finish is painted over, unless 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 Manufacturer.
THIS LIMITED WARRANTY COVERS A CONSUMER PRODUCT AS DEFINED BY THE MAGNUSON-MOSS ACT. NO WARRANTIES, EXPRESS OR IMPLIED
(INCLUDING BUT NOT LIMITED TO THE WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE) WILL EXTEND BEYOND THE TIME
PERIOD SET FORTH IN UNDERSCORED BOLD FACE TYPE IN THIS LIMITED WARRANTY, ABOVE.
•
Some States do not allow limitations on how long an implied warranty lasts, so the above limitations may not apply to you.
Any claim under this Limited Warranty must be made in writing, within the applicable warranty period, to the dealer from which the product was
purchased. Unless the dealer is no longer in business, a written claim to the Manufacturer will be the same as if no claim had been made at all.
At the Manufacturer’s option, a service representative may inspect the product on site, or Buyer may be required to return the product to the
Manufacturer at Buyer’s expense. Buyer agrees to cooperate with any representative of the Manufacturer and to give such representative full access to the
product with the claimed defect and full access to the location of its installation.
If the Manufacturer determines that the claim is valid under the terms of this Limited Warranty, the Manufacturer will repair or replace the defective
product. The decision about the manner in which the defect will be remedied will be at the discretion of the Manufacturer, subject to applicable law. THE
REMEDY WILL COVER ONLY MATERIAL. THIS LIMITED WARRANTY DOES NOT COVER OTHER CHARGES, SUCH AS FIELD SERVICE LABOR FOR REMOVAL,
INSTALLATION, PAINTING, SHIPPING, ETC.
Any repairs or replacements arranged by Manufacturer will be covered by (and subject to) the terms, conditions, limitations and exceptions of this
Limited Warranty; provided, however, that the installation date for the repaired or replaced product will be deemed to be the date the original product was
installed, and this Limited Warranty will expire at the same time as if there had been no defect. If a claim under this Limited Warranty is resolved in a manner
other than described in the immediately preceding paragraph, then neither this Limited Warranty nor any other warranty from the Manufacturer will cover the
repaired or replaced portion of the product.
THE REMEDIES FOR THE BUYER DESCRIBED IN THIS LIMITED WARRANTY ARE EXCLUSIVE and take the place of any other remedy. The liability of the
Manufacturer, whether in contract or tort, under warranty, product liability, or otherwise, will not go beyond the Manufacturer’s obligation to repair or replace,
at its option, as described above. THE MANUFACTURER WILL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
DAMAGES, including (but not limited to) damage or loss of other property or equipment, personal injury, loss of profits or revenues, business or service
interruptions, cost of capital , cost of purchase or replacement of other goods, or claims of third parties for any of the foregoing.
•
Some States do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or

exclusion may not apply to you.
No employee, distributor, dealer, representative, or other person has the authority to modify any term or condition contained in this Limited Warranty or
to grant any other warranty on behalf of or binding on the Manufacturer, and anyone’s attempt to do so will be null and void.
Buyer should be prepared to verify the date of installation to the satisfaction of the Manufacturer.
The rights and obligations of the Manufacturer and Buyer under this Limited Warranty will be governed by the laws of the State of Ohio, USA, to the
extent permitted by law.
•
This Limited Warranty gives you specific legal rights and you may also have other rights, which may vary from State to State.
Covered by one or more of the following Patents; 5,408,724; 5,409,051; 5,419,010; 5,495,640; 5,522,446; 5,562,141; 5,566,740; 5,568,672; 5,718,533; 6,019,269; 6,089,304; 6,644,378; 6,374,567;
6,561,256; 6,527,037; 6,640,872; 6,672,362; 6,725,898; 6,843,300; 6,915,573; 6,951,237; 7,014,386; 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

Please Do Not Return This Product To The Store
Contact your local Wayne-Dalton dealer. To find your local Wayne-Dalton dealer, refer to your local yellow pages
business listings or go to the Find a Dealer section online at www.wayne-dalton.com
Thank you for your purchase
36

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Create Date                     : 2009:08:20 09:09:39-04:00
Modify Date                     : 2009:10:08 09:29:45-04:00
Metadata Date                   : 2009:10:08 09:29:45-04:00
Creator Tool                    : Adobe InDesign CS3 (5.0.4)
Thumbnail Format                : JPEG
Thumbnail Width                 : 256
Thumbnail Height                : 256
Thumbnail Image                 : (Binary data 10295 bytes, use -b option to extract)
Format                          : application/pdf
Producer                        : Adobe PDF Library 8.0
Trapped                         : False
Page Count                      : 36
Creator                         : Adobe InDesign CS3 (5.0.4)

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Wayne Dalton Torquemaster 46 Users Manual

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