Wayne-Dalton Torquemaster Plus User manual

332661 REV1 02/22/2010
TORQUEMASTER® PLUS
REPLACEMENT SPRING(S)
Installation Instructions
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
STANDARD LIFT / FRONT MOUNT LOW HEADROOM
REAR MOUNT LOW HEADROOM
Cable Drum
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
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDERNEATH VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Cable Drum
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
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDERNEATH VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
©Copyright 2010 Wayne-Dalton, a Division of Overhead Door Corporation
Wayne-Dalton, a Division of Overhead Door
Corporation
P.O. Box 67, Mt. Hope, OH 44660
www.Wayne-Dalton.com

2
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:
1. Left Hand End Bracket:
2. Right Hand Spring Assembly:1. Left Hand Spring Assembly:
TABLE OF CONTENTS
TORQUEMASTER® PLUS REPLACEMENT SPRING COMPONENTS FOR
LEFT HAND AND RIGHT HAND ASSEMBLIES
End Bracket
End Bracket
TorqueMaster®
Plus Warning Tags
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
TOOLS NEEDED
Disconnect
Cable Guide
TORQUEMASTER® PLUS END BRACKET IDENTIFICATION
Power Drill Pliers/Wire CuttersRatchet Wrench
Step Ladder LevelLocking Pliers
5/8” Socket
Gloves Pencil
Flat Head Screwdriver
Tape Measure Safety Glasses
3” Extension 7/16” Wrench 7/16” Socket
Driver
Vice Clamps
Left
Right
Warning Tag

3
IMPORTANT! Right and left hand is always determined from inside the
building looking out.
COUNTERBALANCE SPRING TENSION MUST BE RELIEVED BEFORE REMOVING
ANY HARDWARE. A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY
CAN CAUSE SEVERE INJURY.
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.
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.
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.
Single and Double Spring TorqueMaster® Plus Removal
FIG. 1.4
Pawl Knob In
Upper Position
End
Bracket
Pawl
Cable
Drum
Drum
Wrap
Drum
Wrap
Cable Drum
Cable Drum
No space between Ratchet
Pawl and Cable Drum
indicates engagement
Cable Dru
m
Ratchet Pawl
ENGAGED SIDE VIEW
No space between
Ratchet Pawl and
Cable Drum
ENGAGED UNDERNEATH VIEW
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDERNEATH VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions
in the
installation instruc
tions/owners
man
ual.
DO NOT
REMOVE THIS TAG.
End
Bracket
Pawl
Ratchet
3” Extension
Winding
Shaft
5/8”
Socket
Drum
Wrap
Horizontal Track
Assembly
FIG. 1.3
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
Loose
Counterbalance
Cable
Cable
Drum
FIG. 1.2
FIG. 1.1
WARNING
WARNING

4
Cable Drum
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
H VIEW
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
H VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Cable Drum
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
H VIEW
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
H VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Cable Drum
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
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDERNEATH VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Cable Drum
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
H VIEW
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
H VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
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.
Single and Double Spring TorqueMaster® Plus Removal
- Continued
FIG. 1.5
5/16” - 18 x 3/4”
Carriage Bolt
FIG. 1.6
FIG. 1.8
FIG. 1.7
FIG. 1.9 FIG. 2.0
FIG. 2.1
FIG. 2.2
5/16” - 18
Hex Nut
5/16” x 1-5/8”
Lag Screw
End Bracket
1/4” - 20 x 9/16”
Track Bolt
1/4” - 20 Nut
End Bracket
5/16” - 18 x 1”
Hex Head Screw
5/16” - 18
Hex Nut
Shim
End
Bracket
Rear Support
Bracket
Flat Head Screwdriver
End
Bracket
Locking
Pliers
Winding Shaft
TorqueMaster®
Tube
Bend The
Center
Bracket
Tab Over
Center
Bracket
Center
Bracket
Bushing
TorqueMaster® Tube
TorqueMaster®
Tube
Left Hand
Spring
Right
Hand
Spring
Center
Bracket
Bushing
Loose
Winding
Shaft
Flagangle
Winding
Shaft
Round
Notch
Flagangle
Cable
Drum
TorqueMaster® Tube
Groove
Counterbalance
Cable

5
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® spring tube assembly are cam shaped to fit
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.
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® spring
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.
TorqueMaster® Plus Single and Double Spring Replacement
FIG. 2.3
FIG. 2.6
Perch
Left Hand
Spring
Right Hand
Spring
TorqueMaster®
Tube
Bend The Center Bracket
Tab Over Center Bushing
Center Bracket Bushing
Center Bracket Bushing
Level
TorqueMaster®
Tube
Winding
Shaft
5”
TorqueMaster®
Spring Tube
Assembly
FIG. 2.4
TorqueMaster®
Tube
Drum Wrap
Right Drum Wrap
Left Drum Wrap
FIG. 2.5
TorqueMaster®
Tube
TorqueMaster Labeled End

6
Cable Drum
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
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDERNEATH VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
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.
THE TORQUEMASTER® TUBE IS NOT INTENDED TO
SUPPORT WEIGHT. TO AVOID SEVERE OR FATAL INJURY,
DO NOT HANG ANY OBJECTS FROM REAR MOUNTED
TORQUEMASTER® TUBE.
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.
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.
FAILURE TO PLACE VICE CLAMPS ONTO VERTICAL TRACK
CAN ALLOW DOOR TO RAISE AND CAUSE SEVERE OR
FATAL INJURY.
TorqueMaster® Plus Single and Double Spring Replacement
- Continued
Winding Shaft
Cable Drum
Groove
Round Notch
Flagangle
Splines
Counterbalance
Cable
Loose Winding Shaft
Groove In
Flagangle
Cable
Drum
Winding
shaft
Splines
FIG. 2.7
FIG. 2.8
FIG. 2.9
Set Screw
Counterbalance Cable In
First Groove
Cam Peak Strait Up
Counterbalance
Cable
FIG. 3.0
Adapter
Bracket
Round Notch
Winding Shaft
Winding Shaft
Groove
Drum Spacer
(Factory Installed)
TorqueMaster®
Tube
WARNING
WARNING

7
Cable Drum
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
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDERNEATH VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in conjunction with the Ins
tructions on the other side of
this label.
WA
RNING
Rachet B
racket is under
E
XTREME SPRING
TENSION.
To avoid possible severe 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 THIS TAG.
Cab
le Drum
No space between Ratchet
Pawl and Cable Drum
indicates engagement
Cable Drum
Ratchet Pawl
ENGAGED SIDE VIEW
No sp
ace between
Ratche
t Pawl and
Cabl
e Drum
ENGAGED UNDERNEATH V
IEW
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No spa
ce between
Ratche
t Pawl and
DISENGAGED UNDERNEATH
VIEW
UPPER POSITIO
NLOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSIT
ION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Uppe
r Position
Use these Illustration, in c
onjunction with the Instructions on the other side of
this label.
WARNING
Rac
het Bracket is under
EXTREME SPRING
TENSION.
To
avoid possible severe or
fatal in
jury, DO NOT remove
fasteners from ratchet bracket
unti
l spring(s) are fully
wnwound.
To sa
fely unwind spring(s)
read
and fol
low the directions in the
inst
allation instructions/owners
manual.
DO NO
T REMOVE THIS TAG.
Cable Drum
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
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDERNEATH VIEW
UPPER POSITION
LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
Splines
Winding
Shaft
Groove
Disconnect
Cable Guide Hole
Right End
Bracket
Warning
Tag
Right End
Bracket
Ratchet Wheel
Teeth
Pointing
Upward
5/16” x 1-5/8”
Hex Head Lag
5/16” - 18 x 3/4”
Carriage Bolt And
Hex Nut
Right End
Bracket
Warning
Tag
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
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® PLUS
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.
TorqueMaster® Plus Single and Double Spring Replacement
- Continued
FIG. 3.1
FIG. 3.3
FIG. 3.4
FIG. 3.5
Torquemaster® End
Bracket
1/4” - 20 Flange
Hex Nut 1/4” - 20 x 9/16”
Track Bolt
Torquemaster®
Shim
5/16” - 18
Hex Nut
5/16” - 18 x 1”
Hex Head Bolt Adapter Bracket
Torquemaster®
End Bracket
Torquemaster®
Shim
FIG. 3.2
WARNING

8
Cable Drum
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
Space between Ratchet Pawl
and Cable Drum
non-indicates engagement
Cable Drum
Ratchet Pawl
DISENGAGED SIDE VIEW
No space between
Ratchet Pawl and
DISENGAGED UNDE
RNEATH VIEW
UPPER POSITION LOWER POSITION
LOWER POSITION SIDE VIEW
UPPER POSITION SIDE VIEW
Ratchet Pawl in Lower Position
Ratchet Pawl in Upper Position
Use these Illustration, in 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
wnwound.
To safely unwind spring(s)
read
and follow the directions in the
installation instructions/owners
manual.
DO NOT REMOVE THIS TAG.
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
Number of Installed Spring Turns
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.
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.
TorqueMaster® Plus Single and Double Spring Replacement
- Continued
End Bracket
Ratchet
3”
Extension
5/8” Socket
Marks
Pawl Knob In
Lower Position
End Bracket
Pawl Knob In
Upper Position
End Bracket
Drum Wrap
(Left Hand)
Drum
(Left Hand)
Counterbalance
Cable Groove
In Drum
Tabs
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. 3.6
FIG. 3.8 FIG. 3.9
FIG. 4.0
FIG. 4.1
FIG. 3.7