Page 1
TORQUEMASTER® PLUS
REPLACEMENT SPRING(S)
Wayne-Dalton, a Division of Overhead Door
Corporation
Installation Instructions
P.O. Box 67, Mt. Hope, OH 44660
www.Wayne-Dalton.com
These installation instructions are to be used as a supplement to the main Installation Instructions and Owner’s Manual provided with the door. The
instructions included in this document are ONLY those which deviate from the standard installation. All WARNINGS and CAUTIONS listed in the main
manual are applicable to these instructions as well.
TORQUEMASTER® PLUS
r side of
the othe
ions on
nstruct
NING
the I
ion with
G
WAR
W
cket is under
VIE
in conjunct
SIDE
.
tration,
ENGAGED
Rachet Bra
Illus
remove
EXTREME SPRIN
TENSION
acket
rum
bel.
Use these
y
Cable D
chet br
ull
DO NOT
this la
)
To avoid possible severe or
d.
ring(s
fatal injury,
tchet
Ra
fasteners from rat
wnwoun
until spring(s) are f
etween
Drum
ace b
ment
d Cable
read
No sp
rections in the
engage
ns/owners
t Pawl
Pawl an
che
To safely unwind sp
Rat
IEW
indicates
TH V
l.
RNEA
THIS TAG.
NDE
manua
and follow the di
ENGAGED U
installation instructio
REMOVE
etween
W
DO NOT
nd
wl a
No space b
SIDE VIE
rum
D
AGED
Ratchet Pa
Cable
DISENG
rum
Cable D
awl
Ratchet P
rum
ween
ment
bet
gage
Cable D
Space
and
ates en
ndic
H VIEW
Ratchet Pawl
non-i
RNEAT
E
ND
U
AGED
ON
ITI
DISENG
LOWER POS
etween
nd
wl a
No space b
chet Pa
rum
D
Rat
Cable
TION
SI
UPPER PO
ition
ower Pos
chet Pawl in L
Rat
sition
r Po
VIEW
n Uppe
IDE
ON S
ITI
S
Ratchet Pawl i
ER PO
LOW
W
VIE
SIDE
TION
SI
UPPER PO
NING
WAR
Bracket is under
.
N
Rachet
remove
EXTREME SPRING
TENSIO
possible severe or
chet bracket
DO NOT
To avoid
rom rat
injury,
fatal
the
fasteners f
wnwound.
until spring(s) are fully
wind spring(s)
ons in
read
To safely un
AG.
the directi
l.
follow
manua
and
OVE THIS T
tallation instructions/owners
ins
REM
DO NOT
STANDARD LIFT / FRONT MOUNT LOW HEADROOM
NING
under
ING
WAR
cket is
.
E SPR
Rachet Bra
remove
ble severe or
EXTREM
TENSION
bracket
chet
DO NOT
To avoid possi
(s)
fatal injury,
spring
l spring(s) are fully
fasteners from rat
wnwound.
in the
unti
read
ons/owners
To safely unwind
low the directions
instructi
THIS TAG.
manual.
lation
and fol
instal
DO NOT REMOVE
REAR MOUNT LOW HEADROOM
©Copyright 2010 Wayne-Dalton, a Division of Overhead Door Corporation
332661
of
er side
the oth
s on
Instruction
with the
ion
WARNING
onjunct
VIEW
SIDE
.
AGED
tration, in c
ENG
Rachet Bracket is under
remove
EXTREME SPRING
TENSION
hese Illus
Drum
Use t
le
Cab
DO NOT
this label.
tchet bracket
To avoid possible severe or
njury,
ing(s)
fatal i
t
pring(s) are fully
Ratche
fasteners from ra
wnwound.
m
until s
between
ble Dru
space
ely unwind spr
read
No
l and Ca
wl
engagement
saf
Paw
directions in the
cates
To
Ratchet Pa
indi
H VIEW
T
RNEA
NDE
U
manual.
and follow the
AGED
ENG
installation instructions/owners
n
betwee
DO NOT REMOVE THIS TAG.
space
awl and
SIDE VIEW
No
t P
Ratche
le Drum
Cab
DISENGAGED
le Drum
Cab
l
het Paw
atc
um
een R
betw
gagement
Cable Dr
l
Space
and
Paw
cates en
IEW
H V
Ratchet
non-indi
RNEAT
NDE
U
AGED
TION
DISENG
OSI
LOWER P
between
space
No
t Pawl and
Ratche
e Drum
Cabl
TION
OSI
UPPER P
ition
Lower Pos
l in
Paw
Ratchet
Upper Position
wl in
OSITION SIDE VIEW
Ratchet Pa
LOWER P
E VIEW
SID
TION
ER POSI
UPP
REV1 02/22/2010
Page 2
TABLE OF CONTENTS
TorqueMaster® Plus Replacement Spring Components 2
TorqueMaster® Plus End Bracket identification .......... 2
Tools Needed ............................................................. 2
Single And Double Spring TorqueMaster® Plus Removal 3-4
TorqueMaster® Plus Single And Double Spring Replacement 5-8
TORQUEMASTER® PLUS REPLACEMENT SPRING COMPONENTS FOR
LEFT HAND AND RIGHT HAND ASSEMBLIES
2. Right Hand Spring Assembly:1. Left Hand Spring Assembly:
Left
Right
TORQUEMASTER® PLUS END BRACKET IDENTIFICATION
1. Left Hand End Bracket:
End Bracket
Warning Tag
NOTE: A TorqueMaster® Plus single spring system can be identified by the end brackets. You can identify the right hand end bracket by the disconnect cable
guide hole in the top of the bracket, as shown above. The left hand end bracket will have no disconnect cable guide hole in the top of the bracket.
2. Right Hand End Bracket:
Disconnect
Cable Guide
TorqueMaster®
Plus Warning Tags
End Bracket
Power Drill Pliers/Wire CuttersRatchet Wrench
Tape Measure Safety Glasses
5/8” Socket
3” Extension 7/16” Wrench
Gloves Pencil
TOOLS NEEDED
Step Ladder LevelLocking Pliers
2
Flat Head Screwdriver
7/16” Socket
Driver
Vice Clamps
Page 3
Single and Double Spring TorqueMaster® Plus Removal
in the
tions/owners
REMOVE THIS TAG.
IMPORTANT! Right and left hand is always determined from inside the
building looking out.
WARNING
COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING
ANY HARDWARE. A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY
CAN CAUSE SEVERE INJURY.
Drum
Wrap
Drum
Wrap
Cable
Drum
Cable Drum
Remove the drum wraps from cable drums (if installed) by twisting the drum
wrap while pulling it away from the drum, as shown in Fig. 1.1.
Check for spring tension by pulling the counterbalance cable on the right
hand cable drum away from the header, as shown in Fig. 1.2.
STEP 1: If there is no spring tension the cable will be loose. In addition, the
torque tube should be free to rotate in either direction. If there is no spring
tension, proceed to Step 3. If the counterbalance cable is still taut and the
torque tube is difficult to rotate, that is an indication that spring tension still
exists, proceed to Step 2.
WARNING
IT IS RECOMMENDED THAT LEATHER GLOVES BE WORN WHILE UNWINDING
THE TORQUEMASTER® PLUS SPRINGS. FAILURE TO WEAR GLOVES MAY
CAUSE INJURY TO HANDS.
STEP 2: If there is spring tension and starting with the right hand side,
ensure ratchet pawl knob is in upper position, as shown in Fig. 1.3.
IMPORTANT! PAWL KNOB MUST BE IN UPPER POSITION TO REMOVE SPRING
TENSION, AS SHOWN IN FIG. 1.3.
Place a ratchet with a 5/8” socket on the winding shaft, as shown in Fig. 1.4.
NOTE: A 3” extension is recommended for added clearance from the
horizontal track assembly.
Cable
Drum
Loose
Counterbalance
Cable
FIG. 1.2
FIG. 1.1
Height
6’-0” 14
6’-3” 14-1/2
6’-5” 15
6’-6” 15
6’-8” 15-1/2
6’-9” 15-1/2
7’-0” 16
7’-3” 16-1/2
7’-6” 17
7’-9” 17-1/2
8’-0” 18
End
Bracket
RECOMMENDED
SPRING TURNS
Door
Spring Turns
To remove spring tension, ensure the ratchet and socket is set so that it will
add tension (counter clockwise) on the right hand side and (clockwise) on the
left hand side. Rotate ratchet to relieve pressure between the pawl and the
ratchet wheel. Push in on the pawl to allow the ratchet wheel teeth to pass
by.
CAUTION: BE PREPARED TO HOLD THE FULL TENSION OF THE SPRING.
Gently let the ratchet rotate upward, while watching the number of teeth on
the ratchet wheel pass by the pawl. Remove 3/10 of a turn (watch the 3 teeth
of the ratchet wheel pass the pawl) at a time.
Release the pawl to allow it to engage with the ratchet wheel. Repeat this
process until all spring tension has been removed from spring.
For Double Springs, repeat the same process for the left hand side. Cables
should be loose and the torque tube should be free to rotate in either
direction.
Pawl
Pawl Knob In
Upper Position
FIG. 1.3
End
Bracket
Drum
Wrap
Pawl
Horizontal Track
Assembly
Winding
Shaft
Socket
Use these Illustration,
this label.
EN
5/8”
Ratchet
in conjunction with the Instructions on the other side of
WARNING
Rachet Bracket is under
EXTREME SPRING
ENGA
To avoid possible severe or
GED
SI
TENSION
DE V
fatal injury,
IEW
fasteners from ratchet bracket
.
DO NOT
until spring(s) are fully
remove
To safely unwind spring(s)
3” Extension
GAGED
wnwound.
UNDE
R
and follow the directions
NEATH V
IEW
installation instruc
read
DO NOT
Ratchet Pawl
man
Cabl
e Dru
FIG. 1.4
3
Page 4
Cable
Drum
No space betw
een Ra
tchet
Pawl
and
Cable Drum
indicates engage
ment
Cable
Drum
Ratchet
Pawl
ENGAGE
D SIDE
VIEW
No space
between
Ratchet
Pawl and
Cable Dr
um
H V
IEW
Space b
etween
Ratchet P
awl
and Cabl
e Drum
non-
ind
icate
s engagem
ent
Cable
Drum
Ratchet
Pawl
DISENGAGE
D SIDE
VIEW
No space
between
Rat
chet Pawl
and
H V
IEW
UPPE
R POSIT
ION
LOWER
POSITION
LOWER
POSITION
SI
DE VIEW
Rat
chet Pawl
in Lo
wer Posi
tio
n
Ratchet
Pawl in U
pper Positio
n
Use these
Illustra
tion
, in conj
uncti
on
with the Ins
truc
tions o
n the othe
r side of
this labe
l.
WARNING
Rache
t Bracket
is under
EXT
REME SPRING
TENSION
.
To avoid po
ssible severe
or
fatal i
njury,
DO NOT
remove
fast
ener
s from r
atchet b
racket
until
spring(s) are fu
lly
wnwoun
d.
To safe
ly unwin
d spring
(s)
read
and foll
ow th
e direct
ions in th
e
installatio
n instructio
ns/owners
manua
l.
DO NOT
REMOVE
TH
IS TAG.
Cab
le Drum
No s
pace betwe
en Ratchet
Pawl and C
able Dr
um
indicates engagem
ent
Cable Drum
Ratchet Paw
l
ENG
AGED
SIDE VIEW
No s
pace
between
Rat
chet Pawl
and
Cable Drum
ENGAGED UNDERNEA
TH V
IEW
Space b
etween Ratche
t Pawl
and Cab
le D
rum
non-indicates engagem
ent
Cab
le Drum
Ratchet Paw
l
DISENGA
GED
SIDE VIEW
No s
pace between
Ratchet
Pawl and
DISENGA
GED U
NDERNEAT
H VIEW
UPPER
POSI
TION
LOW
ER POSI
TION
LOW
ER POSITION
SIDE VIEW
UPPER POSI
TION
SIDE VIEW
Ratchet Paw
l in Lower
Position
Ratchet Pawl
in U
pper Po
sition
Use t
hese Illus
tration, i
n conjunction with the Instructions on the other side of
this label.
WARNING
Rachet Bracket is under
EXTREME SPRING
TENSION
.
To
avoid possible severe or
fatal injury,
DO NOT
remove
fasteners from ratchet bracket
until spring(s) are fully
wnwo
und.
To safely unwind spring(s)
read
and follow the directions
in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Single and Double Spring TorqueMaster® Plus Removal
- Continued
NOTE: Spring(s) are fully unwound when counterbalance cables have no
tension.
STEP 3:
Standard Lift/Front Mount Low Headroom Applications:
Starting with the right hand end bracket, first remove the 5/16” - 18 x 3/4”
carriage bolt and one 5/16” - 18 hex nut, then remove the 5/16” x 1-5/8” lag
screw from the end bracket, as shown in Fig. 1.5.
Rear Mount Low Headroom Applications: Starting with the right hand end
bracket, first remove the 1/4” - 20 x 9/16” track bolt and one 1/4” - 20 nut,
then remove the shim, the 5/16” - 18 x 1” hex head screw and the 5/16” - 18
nut from the end bracket, as shown in Fig. 1.6 and Fig. 1.7.
NOTE: DO NOT discard the shim.
Holding the end bracket with a pair of locking pliers, carefully pry the end
bracket from the flagangle/rear support bracket and winding shaft with a flat
head screwdriver, as shown in Fig. 1.8. Repeat for left hand end bracket.
CAUTION: THE WINDING SHAFT MAY ROTATE WHEN REMOVING THE END
BRACKET AND DRIVE GEAR.
Now take note on how many cable drum wraps have been applied to your
cable drum, because your cable drum will need to be rewrapped later. Cable
drums require either 1/2 to 3/4 wraps or 1 1/2 to 1 3/4 wraps.
Bend the center bracket tab over, as shown in Fig. 1.9. Lift right hand side of
the TorqueMaster® tube and slide the cable drum off the tube.
NOTE: The cable drums and springs may be difficult to remove. If so, twist
the cable drum and TorqueMaster® tube to aid removal.
Realign the groove in the winding shaft with the round notch in the flagangle/
rear support bracket and drape the counterbalance cable with drum over the
flagangle/rear support bracket, as shown in Fig. 2.0. Repeat for the other
side. Remove TorqueMaster® tube and gently lay it on the floor, as shown in
Fig. 2.1. Remove the left and right hand spring(s) from the torque tube, as
shown in Fig. 2.2.
NOTE: Single spring application will have no spring on the left hand side, only
a loose winding shaft.
End Bracket
5/16” x 1-5/8”
Lag Screw
5/16” - 18 x 3/4”
Carriage Bolt
Rear Support
Bracket
End
Bracket
5/16” - 18 x 1”
Hex Head Screw
Bend The
Center
Bracket
Tab Over
FIG. 1.5
FIG. 1.7
5/16” - 18
Hex Nut
5/16” - 18
Hex Nut
Use thes
thi
e Illustration,
s label
.
in conjunct
Shim
WARNING
ion w
Rachet
ith t
he Inst
Brack
ructions on the othe
EXT
REM
et i
ENG
AGED SI
s under
E SPR
To
DE VIEW
TEN
r side o
avoi
SION
fatal
ING
f
d possi
injury,
.
fastener
ble s
DO NOT
evere
s from ratc
until
or
remove
spri
het brac
ng(s)
To safely
wnw
are ful
ket
ound.
unwind s
ly
and follow
H V
IEW
read
insta
pring(s
the di
llatio
)
n ins
rec
tions in t
DO NOT
Cable Drum
tructions
Ratchet Pawl
man
he
REMOVE
ual.
/owners
No space
No space
THIS
between
Ratchet Pa
betwee
TAG
Pawl a
wl and
n Ratchet
Cable Drum
nd Cabl
.
indica
e D
tes eng
rum
DISE
agement
NGAGED
SIDE VI
EW
H VIEW
Rat
Cable Drum
chet Pawl
No
space bet
Ratche
Space
ween
between Ratchet Pawl
t Pa
wl and
UPPE
Cable Drum
and Cable Drum
R POSI
non-ind
TION
ica
tes
engagem
ent
LOWER
POSITIO
N
Rat
chet Pawl in Upper
Posi
tion
Rat
chet Pawl in Lower
Position
LOW
ER POSITI
ON
SIDE
VIEW
TorqueMaster®
Tube
End Bracket
1/4” - 20 x 9/16”
Track Bolt
1/4” - 20 Nut
FIG. 1.6
Flat Head Screwdriver
Winding Shaft
FIG. 1.8
TorqueMaster® Tube
Groove
Counterbalance
Cable
Round
Notch
Flagangle
Use thes
thi
e Illustr
s label
.
Locking
Pliers
Flagangle
ation,
in c
WARNING
onjunction w
Rachet
ith t
he Inst
Brack
ructions on the othe
EXT
REM
et i
ENG
AGED SI
s under
E SPR
To
DE VIEW
TEN
r side o
avoi
SION
fatal
ING
f
d possi
injury,
.
fastener
ble s
DO NOT
evere
s f
rom ratc
until
or
remove
spri
het brac
ng(s)
To safely
wnw
are ful
ket
ound.
unwind s
ly
and follow
H VIEW
read
insta
pring(s
the di
llatio
)
n ins
rec
tions in t
DO NOT
Cable Drum
tructions
Ratchet Pawl
man
he
REMOVE
ual.
/owners
No space
No space
THIS
between
Ratchet Pa
betwee
TAG
Pawl a
wl and
n Ratchet
Cable Drum
nd Cable Drum
.
indica
tes eng
DISE
agement
NGAGED
SIDE VIEW
H VIEW
Rat
Cable Drum
chet Pawl
No
space bet
Ratchet Pa
Space
ween
between Ratchet Pawl
wl and
UPPE
Cable Drum
and Cable Drum
R POSI
non-ind
TION
ica
tes
engagem
ent
LOWER
POSITIO
N
Rat
chet Pawl in Upper
Posi
tion
Rat
chet Pawl in Lower
Position
LOW
ER POSITI
ON
SIDE
VIEW
End
Bracket
Winding
Shaft
Cable
Drum
TorqueMaster® Tube
Center
Bracket
Bushing
Center
Bracket
FIG. 2.1
Left Hand
Spring
4
FIG. 1.9
FIG. 2.2
FIG. 2.0
Loose
Winding
Shaft
TorqueMaster®
Tube
Center
Bracket
Bushing
Right
Hand
Spring
Page 5
TorqueMaster® Plus Single and Double Spring Replacement
IMPORTANT! RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE
THE BUILDING LOOKING OUT.
Slide the new spring(s), perch end first, into the torque tube (each spring is
identified as to right and left hand, on the perch), as shown in Fig. 2.3. For
single spring applications, there will be no left hand spring inserted into the
TorqueMaster® spring tube assembly.
STEP 1:
If you have a rear mount low headroom counterbalance system, which has
no drum wrap, skip this step and proceed with STEP 2.
NOTE: Drum wraps must be installed prior to installing the TorqueMaster®
Plus end bracket. Drum wrap installation after the end bracket is installed, is
not possible without removing the end bracket and it’s components.
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.
STEP 2:
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, as shown in Fig. 2.4.
Shake the TorqueMaster® spring tube assembly gently to extend the winding
shafts out about 5" on each side, as shown in Fig. 2.5. Lift the torque tube
assembly up and align the center bushing into the center bracket. Check
torque tube for level and adjust if necessary. Bend the center bracket tab
back over the center bushing, as shown in Fig. 2.6.
®
Cable drums and TorqueMaster
together only one way. 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, as shown in Fig. 2.7.
spring tube assembly are cam shaped to fit
®
Perch
Left Hand
Spring
Right Drum Wrap
Left Drum Wrap
TorqueMaster®
Spring Tube
Assembly
Winding
Shaft
TorqueMaster®
Tube
FIG. 2.3
Right Hand
Spring
TorqueMaster®
Tube
Center Bracket Bushing
TorqueMaster Labeled End
Drum Wrap
TorqueMaster®
Tube
FIG. 2.4
Standard Lift/Front Mount Low Headroom Applications:
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, as shown in Fig. 2.9.
Rear Mount Low Headroom Applications:
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 adapter bracket, as shown in Fig. 3.0.
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, as shown in Fig. 2.9.
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
tube assembly, as shown in Fig. 2.9.
Adjust the cable drum assembly by rotating the cable drum to the same
amount of cable drum wraps that was previously made.
NOTE: Cable drums require either 1/2 to 3/4 or 1 1/2 to 1 3/4 wraps.
If cable tension is slack, loosen the set screw no more than 1/2 turn and pull
on the end of the cable to remove all slack. Snug the set screw, then tighten
an additional 1-1/2 turns, as shown in Fig. 2.8.
IMPORTANT! ENSURE THE CABLE IS ALIGNED AND SEATED IN THE FIRST
GROOVE OF THE CABLE DRUM.
For double spring applications: Repeat for opposite side.
®
spring
®
Bend The Center Bracket
Tab Over Center Bushing
TorqueMaster®
Tube
5
5”
FIG. 2.5
Level
Center Bracket Bushing
FIG. 2.6
Page 6
No space between Ratchet
Pawl and Cable Drum
indicates engagement
Cable Drum
Ratchet Pawl
ENGAGED SIDE VIEW
No space between
Ratchet Pawl and
Cable Drum
ENGAGED UNDERNEATH VIEW
DISENGAGED SIDE VIEW
Use these Illustration, in conjunction with the Instructions on the other side of
this label.
WARNING
Rachet
Bracket is
u
nder
EXTREME SPRING
TENSION
.
To avoid possible sever
e or
fatal injury,
DO NOT
remove
fasteners from ratchet bracket
until spring(s) are fully
wnwound.
To safely unwind spring(s)
read
and follow
the directions in the
installation instructions
/owners
manual.
DO NOT
REMOVE T
HIS TAG.
TorqueMaster
®
Plus Single and Double Spring Replacement
- Continued
Groove
Splines
IMPORTANT: WARNING TAGS MUST BE SECURELY ATTACHED TO BOTH END
BRACKETS, AS SHOWN IN FIG. 3.1.
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.
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.
Standard Lift/Front Mount Low Headroom Applications:
Secure end bracket to the flagangle using (1) 5/16” - 18 x 3/4” carriage bolt
and (1) 5/16” - 18 hex nut. Now secure end bracket to the jamb using (1)
5/16” x 1-5/8” hex head lag screw. Repeat for other end bracket.
NOTE: Ensure the 5/16” - 18 x 3/4” carriage bolt is going through the
flagangle first, and the 5/16” - 18 hex nut is on the outside of the end
bracket, as shown in Fig. 3.2.
Rear Mount Low Headroom Applications:
Slide the TorqueMaster
®
shim in between the end bracket and the adapter
bracket. Secure end bracket / shim to the adaptor bracket using one 5/16”
- 18 x 1” hex head bolt and 5/16” - 18 nut, as shown in Fig. 3.4.
NOTE: Ensure the 5/16” - 18 x 1” hex head bolt is going through the end
bracket first, then through the shim and the 5/16” - 18 nut is on the outside
of the opposite side of adaptor bracket, as shown in Fig. 3.4.
Secure end bracket to the adaptor bracket using one 1/4” - 20 x 9/16” track
bolt and 1/4” - 20 flange hex nut, as shown in Fig. 3.5. Repeat for other end
bracket.
NOTE: Ensure the 1/4” - 20 x 9/16” track bolt is going through the adaptor
bracket first, and the 1/4” - 20 flange hex nut is on the outside of the adaptor
bracket, as shown in Fig. 3.5.
WARNING
THE TORQUEMASTER® TUBE IS NOT INTENDED TO
SUPPORT WEIGHT. TO AVOID SEVERE OR FATAL INJURY,
DO NOT HANG ANY OBJECTS FROM REAR MOUNTED
TORQUEMASTER
IMPORTANT: IF RATCHET GEAR SLIPS OUT OF END BRACKET, ENSURE THE
TEETH ON RATCHET WHEEL ARE POINTING UPWARD IN A CLOCKWISE
POSITION WHEN SLIDING IT BACK INSIDE THE END BRACKET, AS SHOWN IN
FIG. 3.3.
®
TUBE.
Cam Peak Strait Up
Counterbalance
Cable
Cable
Drum
Groove In
Flagangle
Winding
shaft
Winding Shaft
Round Notch
Flagangle
FIG. 2.7
Counterbalance Cable In
First Groove
Set Screw
FIG. 2.8
Counterbalance
Cable
Splines
Loose Winding Shaft
FIG. 2.9
IMPORTANT: ENSURE THE CABLE IS ALIGNED AND SEATED IN THE FIRST
GROOVE OF THE CABLE DRUM PRIOR TO WINDING SPRINGS.
Place vice clamps onto both vertical tracks just above the third
roller. This is to prevent the garage door from raising while winding
counterbalance springs.
WARNING
FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK
CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR
FATAL INJURY.
6
Adapter
Bracket
Winding Shaft
Groove
Round Notch
Winding Shaft
FIG. 3.0
TorqueMaster®
Tube
Cable Drum
Drum Spacer
(Factory Installed)
Page 7
tructions on the other side of
RNING
racket
XTREME
le Drum
No s
pace betwe
en Ratchet
Pawl and C
able Dr
um
indicates engagem
ent
Cable Drum
Ratchet Paw
l
ENG
AGED
SIDE VIEW
ace
between
t Pawl
and
e Drum
IEW
Space b
etween Ratche
t Pawl
and Cab
le D
rum
non-indicates engagem
ent
Cab
le Drum
Ratchet Paw
l
DISENGA
GED
SIDE VIEW
ce between
t
Pawl and
VIEW
N
LOW
ER POSITION
Ratchet Paw
l in Lower
Position
r Po
sition
onjunction with the Instructions on the other side of
WARNING
het Bracket is under
EXTREME SPRING
TENSION
.
avoid possible severe or
jury,
DO NOT
remove
fasteners from ratchet bracket
l spring(s) are fully
wnwo
und.
fely unwind spring(s)
read
low the directions in the
allation instructions/owners
manual.
T REMOVE THIS TAG.
LOWER POSITION
TorqueMaster® Plus Single and Double Spring Replacement
- Continued
Splines
Winding
Shaft
Disconnect
Cable Guide Hole
WARNING
IT IS RECOMMENDED THAT LEATHER GLOVES BE WORN
WHILE WINDING THE TORQUEMASTER® PLUS SPRINGS.
FAILURE TO WEAR GLOVES MAY CAUSE INJURY TO
HANDS.
Starting with the right hand side, place a mark on winding shaft (or 5/8”
socket) and end bracket. Turn the pawl knob on the end bracket to the upper
position. Using a ratchet wrench with a 5/8“ socket, wind the spring by
rotating the winding shaft counter clockwise, while watching the mark on the
winding shaft, as shown in Fig. 3.6.
NOTE: A 3” extension is recommended to provide added clearance from the
horizontal angle, as shown in Fig. 3.6.
IMPORTANT: PAWL KNOB MUST BE IN UPPER POSITION TO ADD / REMOVE
REQUIRED NUMBER OF SPRING TURNS, AS SHOWN IN FIG. 3.9.
After 2-3 turns, remove the ratchet wrench and adjust the cable on the left
side, to ensure the cable is in the first groove of the cable drum.
NOTE: Single spring applications require no spring winding on the left hand
side, but does require cable adjustment.
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,
AS SHOWN IN FIG. 3.7
Right End
Bracket
5/16” x 1-5/8”
Hex Head Lag
5/16” - 18 x 3/4”
Carriage Bolt And
FIG. 3.2
Hex Nut
Right End
Bracket
FIG. 3.1
Use t
hese I
this label.
llus
tration, i
n c
Rac
To
fatal in
unti
To
ENGAGED UNDERNEA
sa
and fol
TH V
inst
DO NO
No s
p
Rat
che
Cabl
Pointing
DISENGA
GED U
NDERNEAT
H
Upward
No s
pa
Ratche
UPPER
Cab
POSI
TIO
Ratchet Pawl
in U
ppe
UPPER POSI
T
Right End
Bracket
Teeth
Ratchet Wheel
FIG. 3.3
Use these Illustr
this label.
ation, in conjunction with the Ins
Rachet B
Use these Illustration, in conjunction with the Instructions on the other side of
this label.
ENGAGED UNDERNEATH VIEW
DISENGAGED U
Groove
Warning
Tag
WA
E
Warning
Tag
WARNING
Rachet Bracket is under
EXTREME SPRING
ENGAGED SIDE VIEW
To avoid possible severe or
TENSION
fatal injury,
fasteners from ratchet bracket
.
DO NOT
until spring(s) are fully
remove
To safely unwind spring(s)
wnwound.
and follow the directions in the
installation instructions/owners
read
DO NOT REMOVE THIS TAG.
Ratchet Pawl
manual.
No space between
Ratchet Pawl and
Cable Drum
DISENGAGED SIDE VIEW
NDERNEATH VIEW
Ratchet Pawl
No space between
Ratchet Pawl and
UPPER POSITION
Cable Drum
No space between Ratchet
Pawl and Cable Drum
indicates engagement
Space between Ratchet Pawl
non-indicates engagement
Cable Drum
Cable Drum
and Cable Drum
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, as shown
in Fig. 4.0.
For double spring applications:
Place a mark on the winding shaft and end bracket. Place the ratchet with
5/8” socket 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, as
shown in Fig. 4.0.
IMPORTANT: MARK NUMBER OF SPRING TURNS ON TORQUEMASTER
END BRACKET WARNING TAG(S), as shown in Fig. 3.8.
NOTE: Since total turns to balance door may deviate from SPRING TURN
CHART values by ± 1/2 turn, adjustments to the recommended number of
turns may be necessary.
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.
®
PLUS
5/16” - 18
Hex Nut
Torquemaster®
Shim
Torquemaster®
Shim
1/4” - 20 Flange
Hex Nut
7
5/16” - 18 x 1”
Hex Head Bolt
Torquemaster®
End Bracket
Adapter Bracket
FIG. 3.4
Torquemaster® End
Bracket
1/4” - 20 x 9/16”
Track Bolt
FIG. 3.5
Page 8
TorqueMaster® Plus Single and Double Spring Replacement
- Continued
Now, lift door and check it’s balance. If door raises off the floor under spring
tension alone, then reduce spring tension until door rest on the floor. If the
door is hard to raise or drifts down on its own, then add spring tension.
Anytime spring adjustments are made, ratchet pawl knob must be in the
upper position to add/remove required number of spring turns. To adjust
springs, 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.
IMPORTANT: BE PREPARED TO HOLD THE FULL TENSION OF THE SPRING,
WHEN ADJUSTING SPRING TENSION.
IMPORTANT: DO NOT ADD OR REMOVE MORE THAN 1 SPRING TURN
(1 SPRING TURN EQUALS 10 TEETH ON RATCHET WHEEL) FROM THE
RECOMMENDED NUMBER OF TURNS SHOWN ON THE SPRING TURN CHART.
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 pawl, creating
three “clicks”.
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 pawl and the ratchet wheel. Push
in on the pawl to allow the three ratchet wheel teeth to pass by the pawl, as
you carefully allow the wrench to be rotated upward by the spring tension.
Release the pawl to allow it to engage with the ratchet wheel.
If the door still does not operate easily, lower the door into the closed
position, UNWIND SPRING(S) COMPLETELY, and recheck the following items:
1.) Check the door for level.
End Bracket
Marks
Door Height Spring Turns
(6’ - 0”) 14
(6’ - 3”) 14 - 1/2
(6’ - 5”) 15
(6’ - 6”) 15
(6’ - 8”) 15 - 1/2
(6’ - 9”) 15 - 1/2
(7’ - 0”) 16
(7’ - 3”) 16 - 1/2
(7’ - 6”) 17
(7’ - 9”) 17 - 1/2
(8’ - 0”) 18
Number of Installed Spring Turns
5/8” Socket
FIG. 3.6
Spring Turns
FIG. 3.8
3”
Extension
Use these Illustration, in conjunction with the Instructions on the other side of
this label.
ENGAGED UNDERNEATH VIEW
DISENGAGED U
WARNING
Rachet Brack
EXTREME SPRING
ENGAGED SIDE VIEW
e
t is under
To avoid possible se
TENSION
fatal injury,
fasteners from ratchet bracket
.
DO NOT
until spring(s) are fully
v
ere or
remove
To safely unwind spring(s)
wnwound.
and follow the directions in the
installation instructions/owners
read
DO NOT REMOVE T
Ratchet Pawl
manual.
No space b
Ratchet Pawl and
etween
HIS TAG.
Cable Drum
DISENGAGED SIDE VIEW
NDE
Pawl Knob In
Upper Position
Ratchet
Cable Drum
No space between Ratchet
Pawl and Cable Drum
indicates engagement
End Bracket
RECOMMENDED
SPRING TURNS
Door
Height
Spring Turns
6’-0” 14
6’-3” 14-1/2
6’-5” 15
6’-6” 15
6’-8” 15-1/2
6’-9” 15-1/2
7’-0” 16
7’-3” 16-1/2
7’-6” 17
7’-9” 17-1/2
8’-0” 18
FIG. 3.7
End Bracket
FIG. 3.9
2.) Check the TorqueMaster® tube and flagangles for level and plumb.
3.) Check the distance between the flagangles. It 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.
To install drum wraps, position the left hand drum wrap over the left hand
drum, align with counterbalance cable; slide groove in drum wrap towards
the left until tabs snap over drum in between drum and ratchet gear, as
shown in Fig. 4.1. Repeat for right hand side.
8
Pawl Knob In
Lower Position
Drum
(Left Hand)
Drum Wrap
(Left Hand)
Counterbalance
Cable
FIG. 4.1
FIG. 4.0
Tabs
Groove
In Drum
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