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Tools Needed:

10

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

(2) 1/4”-14 x 5/8” sElf DRIllING sCREWs

NOTE: 

Double car door struts are color 

coded. 18 gauge (.046) have red ends.  20 

gauge (.034) have blue ends.  

bottom Section:
1. 

If your doors windload option code 

begins with 06,

 

place the u-bar with the 

notched ends over the bottom rib of the 

bottom section, notches facing down. 

Center u-bar left to right on section.

If your doors windload option code begins 

with 02,

 

place the u-bar with the notched 

ends over the bottom rib of the bottom 

section, notches facing down. The end 

of the u-bar will fit between the bottom 

bracket flange and the bottom section rib. 

Center u-bar left to right on section.

2.

 fasten the u-bar at each end through 

the top flange with (1) 1/4”-14 x 7/8” 

self drilling screw. If your doors windload 

option code begins with 02,  also fasten 

the u-bar at each end to the bottom 

section rib with  (2) 1/4”-14 x 5/8” self 

drilling screws, through the two holes in 

the bottom bracket flange.

3.

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

screws through each pre-punched hole at 

each intermediate hinge location. 

4.

 Place the u-bar over the top rib of 

the bottom section with the eight pre-

punched holes, facing up.  Center u-bar 

left to right on section.  attach the u-bar 

at each end through the bottom flange 

with (1) 1/4”-14 x 7/8” self drilling screw.

5.

 finish securing the u-bars to the 

section, by placing (2) 1/4” -14 x 5/8” 

self tapping screws midway between the 

end of the door and intermediate hinge 

locations and (1) 1/4” -14 x 5/8” self 

tapping screw approximately eight inches 

from each end.

Intermediate/ Top Section(s):
1.

 Place the u-bar over the top rib of each 

of the remaining sections with the (8) 

pre-punched holes at the ends, facing up. 

Center u-bar left to right on section. 

2.

 fasten the u-bar(s) at each end 

through the top and bottom flange with (2) 

1/4”-14 x 7/8” self drilling screws.  

3.

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

screws through each intermediate hinge.  

4. 

finish securing the u-bar(s) to the 

section, by placing (2) 1/4” -14 x 5/8” 

self tapping screws midway between the 

end of the door and intermediate hinge 

locations and (1) 1/4” -14 x 5/8” self 

tapping screw approximately eight inches 

from each end.

Attaching U-bars

1/4”-14 x 5/8” sElf 

TaPPING sCREWs

u-baR

NOTChED u-baR 

1/4”-14 x 5/8” 
sElf TaPPING sCREWs

1/4”-14 x 7/8” 

sElf DRIllING 

sCREWs

u-baR

Power Drill

7/16” socket 

Driver

saw horses

5

bOTTOM sECTION

INTERMEDIaTE sECTION

INTERMEDIaTE sCREW 

PlaCEMENT

INTERMEDIaTE sCREW 

PlaCEMENT

1/4”-14 x 5/8” sElf 

TaPPING sCREWs

1/4”-14 x 7/8” sElf DRIllING 

sCREWs

fOR OPTION CODEs sTaRTING WITh 02

flaNGE

u-baR

RIb

fOR OPTION CODEs sTaRTING WITh 06

Summary of Contents for TORQUEMASTER 6100

Page 1: ...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 C...

Page 2: ...d 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 da...

Page 3: ...es 21 15 16 or 80 as required u bars as required Q I Jamb Brackets As Required 2 3 8 16 Hex Nuts End Brackets 1 Right 1 Left W ARNIN G Ra ch et Bra cke t is un de r EX TR EM E SP RIN G TE NS IO N To a...

Page 4: ...bels Astragal Warning label Warning labels Hinges are always pre attached at the top of each section except top section The bottom section can be identified by the factory attached bottom astragal and...

Page 5: ...s Safety Glasses Step Ladder PRE INSTALLATION vice grips Vice clamps Gloves 2 Saw Horses Hammer Removing An Existing Door IMPORTANT Counterbalance spring tension must always be released before any att...

Page 6: ...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 IMPORTANT Closely inspect jambs header and mounting sur...

Page 7: ...NLOCKED QUICK INSTALL TAB LOCKED FLAGANGLE VERTICAL TRACK 1 left hand track and flagangle right hand track and flagangle FLAGANGLE VERTICAL TRACK INSTALLATION Installation Begin the installation of th...

Page 8: ...CK hole hole tabs key slot 3 horizontal TRACK tabs horizontal TRACK horizontal angle Attaching Fully Adjustable Flagangles to Vertical Track None 2 NOTE If quick install flagangles were installed in S...

Page 9: ...a 1 4 20 x 9 16 track bolt and nut None JBUS JAMB BRACKET 1 4 20 X 9 16 track bolt 1 4 20 flanged hex nut 4 left side shown right side shown Twistlock TABS Top hole Bottom hole Middle hole quick insta...

Page 10: ...Bar over the top rib of the bottom section with the eight pre punched holes facing up Center U Bar left to right on section Attach the U Bar at each end through the bottom flange with 1 1 4 14 x 7 8...

Page 11: ...Handle Placement reference on single wide doors On single doors locate and mark the horizontal and vertical center on the bottom rail of the bottom section Center the pull handle using the vertical an...

Page 12: ...sly made center line mark Measure the height of the panel Divide that measurement in half and mark a horizontal line intersecting the vertical line s previously marked Measure up 3 7 8 from the inters...

Page 13: ...ng of roller slide on U bars Place roller slides on the sections as follows Lock Section second section use the second set of holes Intermediate Section Third section use the third set of holes Fasten...

Page 14: ...ilot holes into the jambs for the lag screws Loosely fasten jamb brackets and flagangle to the jamb using 5 16 x 1 5 8 lag screws Tighten lag screw securing bottom jamb bracket to jamb to maintain 5 8...

Page 15: ...d and fasten center hinges first and end hinges last with 1 4 14 x 5 8 self tapping screws Repeat for other section s except top section IMPORTANT Push hold the hinge leaf against section while securi...

Page 16: ...s and nuts Note Install the track bolts as far apart as possible as shown when fastening the top bottom halves together NOTE For retro fit applications the adjustable operator bracket must be aligned...

Page 17: ...e top section Now flip up hinge leafs hold tight against section and fasten center hinges first and end hinges last Refer to Step 12 Position flagangle between 1 11 16 43 mm to 1 3 4 44 mm from the ed...

Page 18: ...ING SEVERE OR FATAL INJURY Level the horizontal track assembly and bolt the horizontal angle to the slot in the flagangle using 1 3 8 16 x 3 4 truss head bolt and 1 3 8 16 hex nut Repeat for other sid...

Page 19: ...20 x 9 16 track bolts and 2 1 4 20 flange hex nuts DO NOT RAISE DOOR UNTIL HORIZONTAL TRACKS ARE SE CURED AT REAR AS OUTLINED IN STEP 28 OR DOOR COULD FALL FROM OVERHEAD POSI TION CAUSING SEVERE OR FA...

Page 20: ...he floor inside garage in front of the door with the labeled end to the left LABELED END TorqueMaster Spring Tube None 19 18 Adjusting Top Roller Slide With horizontal tracks installed you can now adj...

Page 21: ...er Spring Tube TorqueMaster Spring Tube CENTER BRACKET BUSHING INSTALLATION 21 IMPORTANT RIGHT AND LEFT HAND IS ALWAYS DETERMINED FROM INSIDE THE GARAGE LOOKING OUT Drum wraps are identified as right...

Page 22: ...n 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 ra...

Page 23: ...l and Cable Drum indica tes engag emen t Cable Drum Ratch et Pawl ENGA GED SIDE VIEW No space betwe en Ratch et Pawl and Cable Drum ENGA GED UNDE RNEA TH VIEW Space betwe en Ratch et Pawl and Cable Dr...

Page 24: ...ing Winding Track Vice Clamps WARNING 24 place vice clamps above 3rd Roller Check to ensure the cable is aligned and seated in the first and second groove of the cable drum Snug the set screw and then...

Page 25: ...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 wrench and adjust the cable on the left side Ensure...

Page 26: ...ing the black tooth on the ratchet wheel or 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 h...

Page 27: ...parallel to the door within 3 4 maximum of door edge Keep horizontal track parallel and within 3 4 maximum of door edge otherwise door could fall resulting in severe or fatal injury IMPORTANT DO NOT S...

Page 28: ...tension Release the pawl to allow it to 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 TURNS 1 SPRING TURN...

Page 29: ...PERSON IS UNAWARE OF THE SLACK CABLES AND THE ENGAGED TORQUEMASTER PLUS SAFETY SYSTEM AND ACTIVATES THE MIS ADJUSTED OPENER DAMAGE WILL LIKELY OCCUR TO THE DOOR AND OPENER THE POTENTIAL ALSO EXISTS T...

Page 30: ...system is engaged see illustration 2 Disengage the opener if installed by pulling or placing the emergency disconnect in the manual operated position 3 With assistance raise the door to the fully open...

Page 31: ...inding 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...

Page 32: ...oximately 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 w...

Page 33: ...FATAL INJURY 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 rai...

Page 34: ...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 w...

Page 35: ...r Painting the wood surfaces with at least 2 coats of finish paint over the primer Follow paint manufacture s label directions completely for all coatings Once finished remove painter s tape and touch...

Page 36: ...ure 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 ordinar...

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