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5120 anD 5140
®
TorqueMaster - Single and Double Spring
Installation Instructions and Owner’s Manual
IMPORTanT nOTICE!
Wayne-Dalton Corp.
Read these instructions carefully before
P.O. Box 67
attempting installation. If in question about
Mt. Hope, OH 44660 any of the procedures, do not perform the
work. Instead, have a qualified door agency
www.wayne-dalton.com
do the installation or repairs.
Copyright 2009 Wayne-Dalton Corp. Part No. 325812 REV3 08/03/2009
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wARNINg READ ThESE Table of Contents Important safety Instructions .................................................. 2 INSTRUCTIONS CAREfUlly bEfORE Package Contents ................................................................... 3 ATTEMPTINg INSTAllATION. If Door section Identification ...................................................... 4 Tools Required ........................................................................ 5 IN qUE
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NOTE: DEPENDING ON ThE DOOR MODEl, sOME P aRTs lIsTED WIll NOT BE suPPlIED IF NOT Package Contents NECEssaR y. REaR suPPORTs May OR May NOT BE INCluDED WITh yOuR DOOR. DOOR sECTIONs (as REquIRED) (2) hORIzONTal aNGlEs (21-15/16” OR 80”) ® (1)TORquEMasTER sPRING TuBE (as REquIRED) (2) quICk INsT all Rh/lh (2) hORIzONTal TRaCks Rh/lh FlaGaNGlE (as REquIRED) RIGhT aND lEFT CaBlE ® (2) TOP BRaCkET slIDEs asyMMETRICal u-BaR u-BaR IDRIVE OPERaTOR DRuM assEMBlIEs (IF INCluDED) (IF INCluDED) (sOlD s
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Door Section Identification WaRNING laBEl NOTE: This provides an alternative method Tools Needed: for identifying your door sections/stack position. TOP sECTION #3 hinges are always pre-attached at the top END sTIlEs of each section (except top section) and the hinges are stamped for identification, #1, #2, #3, and #4 (#4 only on five WaRNING laBEls section doors). see view below. The stamp identifies the stacking sequence of the section. The sequence is always INTERMEDIaTE sECTION deter
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Tools Required POWER DRIll RaTChET WRENCh PlIERs/WIRE CuTTERs TaPE MEasuRE 1/8”, 3/16” DRIll BITs PhIllIPs hEaD sCREWDRIVER Fla T TIP sCREWDRIVER PENCIl NEEDlE NOsE PlIERs GlOVEs 3/8”, 7/16”, 1/2”, 9/16” 7/16”, 1/2”, 9/16” 7/16” sOCkET DRIVER saFETy GlassEs sOCkETs WRENChEs sTEP laDDER haMMER VICE GRIPs VICE ClaMPs (2) sa W hORsEs Removing An Old Door wARNINg IF yOuR COuNTERBalaNCE sysTEM Is OThER ThaN ThOsE MENTIONED IN sECTIONs P1, P2 aND P3, DO NOT aTTEMPT TO WORk ON IT, BuT ha VE a qualIFI
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sET sCREWs Torsion Spring Removal P1 for Standard lift Tools Needed: wARNINg FaIluRE TO usE aPPROVED Recommended WINDING BaRs CaN CausE tools from sPRING ENERGy TO BE RElEasED page 5 FIRMly hOlD WINDING suDDENly, REsul TING IN sEVERE BaR aND CauTIOusly OR FaTal INjuR y. lOOsEN sET sCREWs wARNINg COuNTERBalaNCE sPRING TENsION MusT BE RElIEVED BEFORE REMOVING aNy WINDING CONE haRDWaRE. a POWERFul sPRING RElEasING IT’s ENERGy suDDENly CaN CausE sEVERE OR FaTal INjuR y. Do not release
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lOOsEN lOCk NuT COuNTER ® TorqueMaster Spring Removal GEaR/ COVER P2 ® a TorqueMaster spring system can be Tools Needed: identified by the end brackets. For single spring applications, the right hand end RIGhT haND Recommended bracket will always have a drive gear, END BRaCkET tools from counter gear, counter cover, and a winding bolt head. The left hand end bracket will page 5 have no gears, counter cover, or winding bolt head. The hole for the winding bolt head will be plugged. For
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® TorqueMaster Spring Removal continued... If the counterbalance cable is still taut and Tools Needed: ® the TorqueMaster spring tube is difficult to rotate, that is an indication that spring Recommended tension still exists on the left hand spring. tools from Repeat steps 1 and 2 for releasing spring page 5 tension on the left hand side. Step 4: using a flat tip screwdriver, pry REMOVE TOP the counter gear and counter cover laG sCREW from the right hand end bracket (Fig. 4 fig. 5 on
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REMOVE laG sCREW FROM saFETy CaBlE (IF Extension Spring Removal INsTallED). REPEa T FOR P3 OPPOsITE sIDE. Step 1: Raise the door to the fully open Tools Needed: position and place vice clamps to the back Recommended legs of both vertical tracks, below the tools from bottom rollers to prevent the door from page 5 falling. By opening the door you release most of the spring tension. Carefully BOTTOM sECTION unfasten the s-hook from the horizontal (DOOR OPEN) angle. Remove cable, sheave and
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suITaBlE MOuNTING suRFaCE 2” x 6” Preparing the Opening luMBER MINIMuM hEaDER BOaRD P5 2” x 6” luMBER PREFERRED Tools Needed: If you just removed your existing door or you are installing a new door, complete all steps in PREPaRING ThE OPENING. Recommended To ensure secure mounting of track brackets, side and center DOOR tools from hEIGhT brackets, or steel angles to new or retro-fit construction, it is lEVEl hEaDER page 5 recommended to follow the procedures outlined in DasMa PluMB j
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Installation IMPORTANT: REaD INsTR uCTIONs TITlED “P4” “REMOVING ThE OlD DOOR” ON P aGE 9 aND “P5” “PREPaRING ThE OPENING” ON PaGE 10 BEFORE aTTEMPTING DOOR INsTalla TION. IMPORTANT: sTaINlEss sTEEl OR PT2000 COa TED laG sCREWs MusT BE usED WhEN INsTallING CENTER BEaRING BRaCkETs, END BRaCkETs, jaMB BRaCkETs, OPERa TOR MOuNTING/suPPORT BRaCkETs aND DIsCONNECT BRaCkETs ON TREaTED luMBER (PREsERVaTIVE-TREaTED). sTaINlEss sTEEl laG sCREWs aRE NOT NECEssaR y WhEN INsTallING PRODuCTs ON uN-TREa TE
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hORIzONTal hOlE TaBs aNGlE horizontal Angle 2 kEy slOT Tools Needed: Position the horizontal angle as shown. Place tabs of horizontal angle in the key hammer slot of horizontal track. using a hammer, tap the horizontal angle towards the curved end of the track until the holes in hORIzONTal TRaCk track and angle are aligned. set tracks hOlE aside. hORIzONTal TRaCk NOTE: For larger doors, a full length horizontal angle may be spot welded to the horizontal track. If the horizontal angle i
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® lEFT haND TORquEMasTER #1 END hINGE COuNTERBalaNCE DR uM (hINGE TuBE) Drums 4 IMPORTANT: RIGhT aND lEFT haND Is Tools Needed: al Ways DETERMINED FROM INsIDE ThE None BuIlDING lOOkING OuT . BOTTOM BOTTOM NOTE: For door section identification see sECTION sECTION page 4. COuNTERBalaNCE ® CaBlE TorqueMaster counterbalance drums are marked right and left hand. uncoil the ROllERs counterbalance cables and make sure you place the right hand cable loop on the right hand milford pin and pla
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CaBlE DR uM VERTICal TRaCk FlaGaNGlE BOTTOM sECTION vertical Track 6 Tools Needed: IMPORTANT: ThE TOPs OF ThE 5/16” x 1-5/8” VERTICal TRaCks MusT BE lEVEl 3/16” Drill Bit laG sCREWs FROM sIDE TO sIDE. IF ThE BOTTOM Power Drill sECTION Was shIMMED TO lEVEl IT . CaBlE 5/8” ROllER 7/16” socket ThE VERTICal TRaCk ON ThE shIMMED Driver sIDE, MusT BE RaIsED ThE hEIGhT OF ThE shIM. Tape Measure VERTICal TRaCk level Position the left hand vertical track assEMBly laG assembly over the roller
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1sT sET TOP sECTION Top brackets 8 (4) 1/4” - 14 x 5/8” 2ND sET sElF T aPPING Tools Needed: To install the l-shaped top brackets, sCREWs align the top holes in the top bracket Power Drill TOP BRaCkET BasE base with the second set of holes in the 7/16” socket endcap. Driver Fasten using (4) 1/4” - 14 x 5/8” self tapping screws. secure the top bracket (2) 1/4” - 20 x 5/8” CaRRIaGE BOl Ts slide to the bracket base loosely using (2) 1/4” - 20 x 5/8” carriage bolts and TOP BRaCkET slIDE (2)
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u-BaR OPERaTOR BRaCkET 6” 6” (INsTallED IN ThE sTEP 11) U-bar - Asymmetrical 10 30” TO 36” Tools Needed: NOTE: If a 3” u-bar was installed in step 9, skip this step. Power Drill 7/16” socket NOTE: Model 5120 or 5140 glazed top (2) 1/4”-14 x 5/8” Driver doors 13’-0” wide or greater will be u-BaR sElF TaPPING supplied with a 3” asymmetrical u-bar (2) 1/4”- 14 x 5/8” sElF sCREWs for the top section. TaPPING sCREWs (2) 1/4”-20 x 11/16” sElF DRIllING Place the 3” asymmetrical u-bar over the
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u-BaR u-BaR OPERaTOR (2) 1/4” - 14 x 5/8” BRaCkET sElF-T aPPING Operator bracket Continued... sCREWs OPERaTOR Tools Needed: Install (2) #12 x 1/2” phillips head BRaCkET screws on the opposite side of operator bracket, as shown in FIG. 1.3. Clamp operator bracket to u-bar (if furnished), as shown in FIG. 1.4. First attach (3) 1/4” - 14 x 5/8” self-tapping screws to the operator bracket, as shown in FIG. 1.5. Then attach (2) 1/4” - 14 x 5/8” (2) 1/4” - 20 x 11/16” (3) 1/4” - 14 x 5/8”
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FlaGaNGlE FlaGaNGlE Attaching horizontal Track to quick Install flagangle 13 kEy quICk Tools Needed: To install horizontal track, place the INsTall slOT curved end over the top roller. align key TaB 9/16” socket slot of the horizontal track with the quick hORIzONTal install tab of the flagangle. Push curved TRaCk Ratchet Wrench hORIzONTal portion of horizontal track down to TRaCk lock in place. level the horizontal track 9/16” Wrench quICk assembly and bolt the horizontal angle INsT
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® TorqueMaster Spring Tube 15 ® Tools Needed: TorqueMaster springs come lubricated and pre-assembled inside the None ® 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. ® TORquEMasTER sPRING TuBE laBElED END CENTER Center bracket bushing BRaCkET 16 assEMBly ® Tools Needed: NOTE: If you are installing the idrive opener on your garage door, skip this None step and continue with st
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® idrive Installation 17 ® NOTE: see idrive main installation and T Tools ools Needed: Needed: ® owners manual for idrive parts. None IMPORTANT: RIGhT aND lEFT haND Is alWays DETERMINED FROM INsIDE lEFT haND sIDE ® ThE GaRaGE lOOkING OuT. TORquEMasTER sPRING TuBE aND BEaRING PROFIlEs alIGNED MOTOR ® lay the TorqueMaster spring tube on the floor (inside garage) in front of the door with the labeled end to the left. look into the opener’s left side to RIGhT haND END ensure the left
