Wayne Dalton Torquemaster Plus Spring Upgrade Kit Instruction Manual

Introduction

This manual provides comprehensive instructions for the installation and operation of the Wayne Dalton Torquemaster Plus Spring Upgrade Kit. Designed for 7ft high garage doors weighing between 180-189lbs, this kit facilitates the conversion from original Torquemaster (TM1) systems to the newer Plus (TM3/TMII) style. Please read all instructions carefully before beginning installation to ensure safety and proper functionality.

Safety Information

WARNING: Garage door springs are under extreme tension and can cause severe injury or death if handled improperly. Installation should only be performed by individuals with mechanical aptitude and a clear understanding of the risks involved. If you are unsure about any step, consult a qualified garage door technician. Always wear appropriate safety gear, including safety glasses and gloves. Keep children and pets away from the work area.

• Always disconnect the garage door opener from power before beginning any work.
• Never attempt to remove or adjust springs while they are under tension without proper tools and knowledge.
• Ensure all components are securely fastened before operating the garage door.
• Do not operate a garage door with damaged or improperly installed springs.

Product Overview

The Wayne Dalton Torquemaster Plus Spring Upgrade Kit includes the necessary components to replace your existing Torquemaster springs and convert your system to the more modern Plus style. This kit is specifically designed for 7ft high garage doors with a balanced weight between 180-189lbs and includes a double spring set.

Included Components:

• (1) Right-hand wound TorqueMaster Plus spring
• (1) Left-hand wound TorqueMaster Plus spring
• (1) Cable Drum Assembly
• (1) Double Spring Winding Assembly
• Installation reference manual (this document)

Pre-Installation: Determining Your Spring Needs

Before ordering or installing, it is crucial to identify your current Torquemaster system type, door height, and door weight. This kit is for converting original Torquemaster (TM1) to Torquemaster Plus (TM3/TMII).

1. Determine Spring Style (Original vs. Plus)

Identify whether your existing system is an Original Torquemaster (TM TMI) or a Torquemaster Plus (TMII TM3). The winding end of the spring is the key differentiator.

Image: Comparison of Torquemaster Plus (TMII TM3) and Torquemaster Original (TM TMI) spring winding ends. The Plus version has a hexagonal end, while the Original has a splined, round end.

• Torquemaster Plus (TMII TM3): Features a hexagonal winding end. Typically found on doors manufactured after February 2007.
• Torquemaster Original (TM TMI): Features a splined, round winding end.

This upgrade kit is designed to convert Original (TM TMI) systems to the Plus (TMII TM3) style.

2. Measure Door Height

Accurately measure the height of your garage door. This kit is specifically for 7ft high doors.

• For doors measuring between 6'6" and 7'5", select 7ft height.
• For doors measuring between 7'6" and 8'5", select 8ft height (this kit is not for 8ft doors).

You can also check the label on the metal spring tube, which often lists the correct door height.

3. Measure Door Weight

The most critical information for selecting the correct spring is your garage door's balanced weight. This kit is for doors weighing between 180-189lbs.

• Check Spring Tube Label: The weight (Wgt/Bal Wt/Bal Wgt) is usually listed on a label located on the metal tube.
• Weighing the Door: If the label is missing or unreadable, you can weigh your door using a bathroom scale.
  1. Ensure all spring tension is released. The cables must be fully slack on both sides.
  2. Lift the door slightly and slide a bathroom scale under the center.
  3. Lower the door onto the scale, ensuring the full weight is on the scale.
  4. Record the weight.

Selecting a spring with an incorrect weight range will result in improper door balance and potential damage.

Video Guide: How to Order Torquemaster Springs

Installation Instructions

This section outlines the step-by-step process for installing your Wayne Dalton Torquemaster Plus springs. Ensure you have all required tools and have reviewed the safety information.

Required Tools:

• Power drill with socket set
• Ratchet wrench with 5/8 inch socket
• 3-inch socket extension
• Flathead screwdriver
• Phillips screwdriver
• Locking pliers
• Needle-nose pliers
• Stepladder
• Vise clamps

Step 1: Insert the New Springs

1. Slide your new right-hand and left-hand springs into the metal tube, perch end first.
2. Place the tube back onto the center wall bracket and flag brackets above your door.
3. Ensure the end of each spring hangs out of the tube by approximately 5 inches on each side.
4. Center the tube within the wall bracket.
5. Bend the center tab over the bushing to secure.

Step 2: Install Cable Drums

1. On the right side, ensure the teardrop peak on the tube points straight up.
2. Slide the correct drum over the winding shaft until it is fully seated.
3. Wrap the cables one and a half turns, or align with previous settings.
4. For double springs, repeat this process on the left side.
5. For single springs, insert the idler bracket until it clicks twice and seats flush.
6. If you have a rear-mount low headroom setup, install your drum wraps now. They are labeled Left and Right; ensure the tabs face the correct direction.

Step 3: Mount End Brackets

1. Identify the right end bracket by its cable guide.
2. If the ratchet wheel falls out, reinstall it with the teeth pointing upward (clockwise).
3. Slide the end bracket onto the winding shaft, matching the splines.
4. Ensure the tab is seated.
5. Attach the bracket to the flag angle using a carriage bolt, washer, and nut.
6. Secure it to the jamb with a lag screw.
7. For double springs, repeat on the left side.
8. For single springs, ensure the left drum bearing is tight against the flag angle with no rubbing or gaps, then fasten your idler bracket.

Step 4: Adjust Cables

1. Start on the right side. Rotate the drum until the set screw faces away from the header, and the spring tube peak is straight up.
2. Loosen the set screw about half a turn.
3. Confirm the cable is seated in the first and second grooves.
4. Pull the cable tight to remove any slack. Ensure tension is equal on both sides.
5. Tighten the set screw snug.
6. Add one and a half extra turns to the cable.
7. Trim the excess cable to about 6 inches and insert it into the drum.
8. Repeat this process on the left side.
9. If you are using drum wraps, slide and snap them into place until they click securely.

Step 5: Wind the Springs

1. Place vise clamps on both vertical tracks above the third roller to prevent the door from rising.
2. Use a ratchet with a 5/8 inch socket to wind the springs. Start on the right side.
3. Turn the pawl knob up and rotate counterclockwise to add turns. Mark the shaft to count your turns.
4. After 2 to 3 turns, stop and check cable tension on the left side.
5. Once both sides have even tension, finish winding both sides to the required number of turns for your door height. Refer to the winding chart below.
6. After winding, move the pawl knob down to lock the ratchet.

Winding Chart by Door Height

IMPORTANT: Your door may require slightly different turns than suggested. Make adjustments (± 1/4 turn on each side) as needed until the door is balanced.

Video Guide: How to Install Wayne Dalton TorqueMaster Plus Springs

Operating and Balancing the Door

After installation, it is crucial to test and balance your garage door to ensure safe and efficient operation.

1. Remove the vise clamps from the vertical tracks.
2. Lift the garage door halfway.
3. Observe the door's movement:
   • If the door rises by itself, it has too much tension. Remove turns from the springs (refer to Step 5).
   • If the door is heavy to lift or falls, it has too little tension. Add turns to the springs (refer to Step 5).
4. A properly balanced door should stay in place when lifted halfway.
5. Always move the pawl knob up before making any adjustments to the spring tension.

Once the door is balanced, ensure all connections are tight and cables are aligned before reconnecting your garage door opener.

Maintenance

Regular maintenance helps prolong the life of your garage door springs and ensures safe operation.

• Lubrication: Lubricate springs, rollers, and hinges annually with a silicone-based garage door lubricant. Do not use grease or oil.
• Inspection: Periodically inspect springs for signs of wear, rust, or damage. Check cables for fraying.
• Balance Check: Test the door balance every few months (as described in the "Operating and Balancing the Door" section). Adjust tension if necessary.
• Fasteners: Check all nuts, bolts, and screws for tightness.

Troubleshooting

Here are some common issues and their potential solutions:

Specifications

• Model Number: WD-TMS8186-2-UPKIT
• Door Height Compatibility: 7 ft (for doors 6'6" - 7'5")
• Door Weight Compatibility: Between 180 - 189 lbs
• Spring Type: TorqueMaster Plus (TM3/TMII)
• Spring Life Cycle: Heavy duty 10,000 high cycle life
• Material: Metal
• Item Weight: 12.01 pounds
• Product Dimensions: 12 x 9 x 3 inches

Support and Warranty

For any questions regarding installation, troubleshooting, or product inquiries, please contact Express Garage Doors Inc. This kit includes an installation manual provided by Express Garage Doors, indicating their support for the product.

Specific warranty details are not provided in this document. Please refer to your purchase documentation or contact Express Garage Doors Inc. directly for warranty information.