Door Section Identification; Preparing The Opening - Wayne-Dalton TorqueMaster Plus 6100 Installation Instructions Manual

Top half drawbar Bottom half drawbar
operator bracket operator bracket
(2) 5/16"-18 Hex nuts (2) 3/8"- 16 Hex nuts
1/4"-20 x 9/16"
Track rollers
Track bolts (as required)
(as required)
5/16" x 1 5/8" Hex head lag screws
Drawbar operator
bracket arm
5/16" x 1-1/4" Clevis pin
Pull handles (as required) Lift handles (as required)
#8 x 1-21/32" Quadrex pan head screws

Door Section Identification

Graduated end and center hinges are always pre-attached at the top of each section (except
top section) and the graduated end hinges are stamped for identification, #1, #2, #3, and #4
(#4 only on five section doors). The stamp identifies the stacking sequence of the section.
The sequence is always determined by #1 being the bottom section to #3 or #4 being the
highest intermediate section. If the stamp on the graduated end hinge is illegible, refer to
the section side view illustration. The section side view illustration shows the graduated end
hinge profile of all sections, and can also be used to identify each section.
The BOTTOM SECTION can be identified by #1 graduated end hinges, the factory attached
bottom astragal, the factory attached bottom corner brackets, and by the bottom corner
bracket warning labels on each end stile.
The LOCK SECTION can be identified by #2 graduated end hinges.
The INTERMEDIATE SECTION can be identified by #3 graduated end hinges. The section
will have a warning label attached to either the right or left hand end stile.
NOTE: #4 graduated end hinges are used on the fourth section of five section doors.
The TOP SECTION can be identified with no pre-installed graduated end or center hinges.
Pull down Stud Plate
rope (if included) (as required)
1/4"- 20 Flanged
(2) 5/16" Washers
hex nuts (as required)
(2) 5/16"-18 x 3/4"
Carriage bolts
1/4"-20 x 11/16" Self
(as required) drilling screws (as required)
(2) 3/8"-16 x 3/4" 1/4"-14 x 5/8" Self tapping
Truss head bolts screws (as required)
Cotter pin
#10 x 5/8"
Phillips pan head screws
(black painted heads)
#8 x 1-13/32" Quadrex pan head screws
Warning label
Top section
#3
Warning label
Intermediate section
#2
Lock section
#1
Bottom corner bracket warning labels
Bottom section
Astragal
Typical graduated end
hinge stamping
location
Removing an Existing Door
IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE
ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.
WARNING WARNING
A POWERFUL SPRING RELEASING ITS ENERGY SUDDENLY CAN CAUSE
SEVERE OR FATAL INJURY. TO AVOID INJURY, HAVE A TRAINED DOOR
SYSTEMS TECHNICIAN, USING PROPER TOOLS AND INSTRUCTIONS,
RELEASE THE SPRING TENSION.
For detailed information see supplemental instructions "Removing an Existing Door / Prepar-
ing the Opening". These instructions are not supplied with the door, but are available at no
charge from Wayne Dalton, A Division Of Overhead Door Corporation, P.O. Box 67, Mt. Hope,
OH., 44660, or at www.Wayne-Dalton.com.

Preparing the Opening

IMPORTANT: IF YOU JUST REMOVED YOUR EXISTING DOOR OR YOU ARE INSTALLING A
NEW DOOR, COMPLETE ALL STEPS IN PREPARING THE OPENING.
To ensure secure mounting of track brackets, side and center brackets, or steel angles to
new or retro-fit construction, it is recommended to follow the procedures outlined in DASMA
technical data sheets #156, #161 and #164 at www.dasma.com.
The inside perimeter of your garage door opening should be framed with wood jamb
and header material. The jambs and header must be securely fastened to sound framing
members. It is recommended that 2" x 6" lumber be used. The jambs must be plumb and
the header level. The jambs should extend a minimum of 12" (305 mm) above the top of
the opening for TorqueMaster counterbalance systems. For low headroom applications, the
®
jambs should extend to the ceiling height. Minimum side clearance required, from the open-
ing to the wall, is 3-1/2" (89 mm).
IMPORTANT: CLOSELY INSPECT JAMBS, HEADER AND MOUNTING SURFACE. ANY WOOD
FOUND NOT TO BE SOUND, MUST BE REPLACED.
For TorqueMaster ® counterbalance systems, a suitable mounting surface (2" x 6") must be
firmly attached to the wall, above the header at the center of the opening.
NOTE: Drill a 3/16" pilot hole in the mounting surface to avoid splitting the lumber. Do not
attach the mounting surface with nails.
WEATHERSTRIPS (MAY NOT BE INCLUDED):
Depending on the size of your door, you may have to cut or trim the weatherstrips (if neces-
sary) to properly fit into the header and jambs.
NOTE: If nailing product at 40°F or below, pre-drilling is required.
NOTE: Do not permanently attach weatherstrips to the header and jambs at this time.
3
1-9/16"
#4
Graduated
end hinge
1-3/8"
#3 Graduated
end hinge
1-1/8"
#2 Graduated
end hinge
7/8"
#1 Graduated
end hinge
Bottom corner
bracket
Astragal
Section side view illustration