6100 Light Commercial Door Torsion Spring Installation Instructions and Owner’s Manual Wayne-Dalton Corp. P.O. Box 67 Mt. Hope, OH 44660 www.wayne-dalton.com Copyright 2009 Wayne-Dalton Corp. IMPORTANT NOTICE! Read these 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. Part No.
Table of Contents Important Safety Instructions............................................. 2 Package Contents...........................................................3-4 Door Section Identification................................................. 4 Tools Required................................................................... 5 Pre-Installation...............................................................5-6 Removing The Old Door..................................... 5 Preparing The Opening..........
Package Contents NOTE: Depending on the door model, some parts listed will not be supplied if not necessary. Rear supports may or may not be included with your door.
Door Section Identification Tools Needed: Recommended tools from page 5 Hinges are always pre-attached at the top of each section (except top section) and the hinges are stamped for identification (except double wide end hinges), #1, #2, #3, and #4. See view below. The stamp identifies the stacking sequence of the section. The sequence is always determined by #1 being the bottom section to #4 being the highest intermediate section. See views to the right.
Pencil Power drill Phillips head screwdriver Ratchet wrench 7/16”, 1/2” & 9/16” Socket 9/32”, 1/2”, 3/16” & 1/8” Drill bits Level Sawhorse P1 Flat tip screwdriver Vice grips Safety glasses Tape measure 1/4” Torx bit PRE-INSTALLATION Tools Required Gloves 3/8”, 7/16” Socket driver Hammer 1/4”, 3/8”, 7/16”, 1/2” & 9/16” Wrenches Vice clamps Approved winding bars Step ladder Removing An Old Door IMPORTANT: Counterbalance SPRING TENSION Must always BE Released BEfORE any attempt IS Made
P2 Tools Needed: Recommended tools from page 5 Preparing the Opening WARNING Suitable mounting surface 2” x 6” lumber minimum Header board 2” x 6” lumber recommended FAILURE TO SECURELY ATTACH A SUITABLE MOUNTING PAD TO STRUCTURALLY SOUND FRAMING MEMBER COULD CAUSE SPRINGS TO VIOLENTLY PULL MOUNTING PAD FROM WALL, RESULTING IN SEVERE OR FATAL INJURY. If you just removed your existing door or you are installing a new door, complete all steps in PREPARING THE OPENING.
Installation Begin the installation of the door by checking the opening. It must be the same size as the door. Vertical jambs must be plumb and level with header. Side clearance, from edge of door to wall, must be a minimum of 3-1/2” (89mm) on each side. IMPORTANT: Stainless STEEL OR PT 2000 Coated Lag SCREWS Must BE used When Installing CENTER Bearing Brackets, END Brackets, jamb Brackets, Operator Mounting/Support Brackets and DISCONNECT Brackets ON Treated Lumber (PRESERvaTIvE-TREaTED).
2 Tools Needed: Tape Measure Pencil Power Drill 1/16” Drill Bit Pull Handle Installation NOTE: For door section identification see page 4. Bottom section Locate and mark the horizontal and vertical center on the bottom rail of the bottom section, on single car doors. Center the pull handle using the vertical and horizontal lines as reference on the bottom section rail as shown. Using the pull handle as a template, mark the two holes in the pull handle on the horizontal line of the bottom section rail.
3 Tools Needed: None Counterbalance cable Long shaft roller Counterbalance Cables Bottom section IMPORTANT: Right and left hand is always determined from inside the building looking out. Double wide end hinges NOTE: For door section identification see page 4. WARNING Hinge tube Failure to ensure tight fit of cable loop over milford pin could result in cable coming off the pin, allowing the door to fall, possibly resulting in severe or fatal injury.
5 Tools Needed: 3/16” Drill Bit Power Drill 7/16” Socket Driver Tape Measure Level Step Ladder Vertical track Vertical Track Flagangle IMPORTANT: The tops of the vertical tracks must be level from side to side. If the bottom section was shimmed to level it. The vertical track on the shimmed side, must be raised the height of the shim. Roller Bottom section 3/8” To 5/8” Position the left hand vertical track assembly over the rollers of the bottom section.
7 Tools Needed: Power Drill 7/16” Socket Driver Phillips Head Screwdriver Top section Top Brackets To install the L-shaped top brackets, align the top holes in the top bracket base with the second set of holes in the endcap of the top section. Fasten using (4) 1/4” - 14 x 5/8” self tapping screws. Secure the top bracket slide to the bracket base loosely using (2) 1/4” - 20 x 5/8” carriage bolts and (2) 1/4” - 20 flanged hex nuts.
9 Tools Needed: Power Drill 7/16” Socket Driver 7/16” Wrench Adjustable Operator Bracket Installation IMPORTANT! WHEN CONNECTING A TROLLEY TYPE GARAGE DOOR OPENER TO THIS DOOR, A WAYNE-DALTON OPENER/TROLLEY BRACKET MUST BE SECURELY ATTACHED TO THE TOP SECTION OF THE DOOR, ALONG WITH ANY U-BARS PROVIDED WITH THE DOOR. THE INSTALLATION OF THE OPENER MUST BE ACCORDING TO MANUFACTURER’S INSTRUCTIONS AND FORCE SETTINGS MUST BE ADJUSTED PROPERLY.
10 Tools Needed: Hammer Tape Measure Power Drill 7/16” Socket Driver Step Ladder Top Section Place the top section in the opening and vertically align with lower sections. Door width +3-3/8” to 3-1/2” Temporarily secure the top section by driving a nail in the header near the center of the door and bending it over the top section. Now flip up hinge leaf against section, fastening center hinges first, and end hinges last. (Refer to Step 6).
11 Attaching Horizontal Track to Adjustable Flagangles Tools Needed: 9/16” Socket Ratchet Wrench 9/16” Wrench Level 7/16” Socket Step Ladder To install horizontal track, place the curved end over the top roller. Align the bottom of the horizontal track with the vertical track. Hand tighten the horizontal track to the flagangle with (2) 1/4”-20 x 9/16” track bolts and (2) 1/4”-20 flange hex nuts.
Tools Needed: Step Ladder Power Drill Ratchet Wrench 7/16” Socket Driver 9/16” Socket Driver 9/16” Wrench Torsion End Bearing Brackets End bearing brackets are right and left hand. Break the end bearing brackets apart. Starting on the left hand side and using the upper slots in the end bearing bracket, position above the flagangle and secure the end bearing bracket to the horizontal angle using (2) 3/8”-16 x 3/4” truss head bolts and (2) 3/8”-16 nuts.
15 Torsion Spring Assembly Tools Needed: Step Ladder Important: right and left hand is always determined from inside the building looking out. Note: Identify the springs provided as either right hand wound (red winding cone), which goes on the left hand side or left hand wound (black winding cone), which goes on the right hand side. Facing the inside of the door, lay the torsion tube on the floor.
16 Tools Needed: Step Ladder 9/16” Socket Ratchet Wrench 9/16” Wrench Step Ladder Torsion spring Nylon Center Bushing Slide the nylon center bushing into the stationary spring cone at the end of the spring and align the stationary spring cone(s) with the holes in the center bearing bracket. Secure the spring(s) to the center bearing bracket with (2) 3/8”-16 x 1-1/2” hex head bolts and 3/8”-16 nuts. Important: springs under tension can be Dangerous.
Tools Needed: (2) Vice Clamps Securing Door for Spring Winding 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. WARNING Failure to place vice clamps onto vertical track can allow door to raise and cause severe or fatal injury. Important: Do not use impact gun to wind spring(s).
Winding Torsion Spring(s) Continued... Tools Needed: Carefully remove winding bar from winding cone. Repeat for the opposite spring. While holding the door down, to prevent it from rising unexpectedly, in the event the spring(s) were overwound, carefully remove the vice grips from the torsion tube and the vertical tracks. Important: cautiously remove vice clamps and vice grips from the torsion tube and vertical tracks.
Rear Support Continued... Horizontal track 3/4” To 7/8” Tools Needed: Important: DO NOT SUPPORT The Weight Of The DOOR ON ANY PART Of The horizontal Track hanger That CANTILEVERS 4” OR MORE BEYOND A SOUND framing MEMBER. Note: If rear supports are to be installed over drywall, use 5/16” x 2” hex head lag screws, and make sure lag screws engaged solid structural lumber. Note: 26” Angle must be attached to sound framing members and nails should not be used.
� Tools Needed: Power Drill 7/16” Socket Driver Tape Measure Side Lock Install the side lock on the second section of the door. Secure the lock to the section with (4) 1/4”-20 x 11/16” self drilling screws. Square the lock assembly with the door section, and align with the square hole in the vertical track. The side lock should be spaced approximately 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.
Suitable mounting surface (2” x 6”) lumber minimum Trolley Operator Operator rail WARNING Tools Needed: OPERATOR MUST BE TESTED AT TIME OF INSTALLATION AND MONTHLY THEREAFTER AS DESCRIBED IN YOUR INSTALLATION INSTRUCTIONS AND OWNER’S MANUAL, TO ENSURE THAT DOOR SAFETY FEATURES FUNCTION. FAILURE TO TEST OR MAKE ANY NECESSARY ADJUSTMENTS OR REPAIRS, CAN RESULT IN SEVERE OR 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.
Painting Painting Instructions For Steel and Wood Doors. Steel (Surface Preparation for Painting) Wax 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 wipe and rinse should be done with clean water only, to remove any loose particles and any soapy film residue.
Lifetime Limited Warranty Model 6100 Subject to the terms and conditions contained in this Lifetime Limited Warranty, Wayne-Dalton Corp.
