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6100 Light Commercial Door
Torsion Spring
Installation Instructions and Owner’s Manual
IMPORTANT NOTICE!
Read these instructions carefully before
attempting installation. If in question about
Wayne-Dalton Corp.
any of the procedures, do not perform the
P.O. Box 67
work. Instead, have a trained door systems
Mt. Hope, OH 44660
www.wayne-dalton.com
technician do the installation or repairs.
Copyright 2009 Wayne-Dalton Corp. Part No. 333884 REV2 08/03/2009
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waRNiNg To avoiD PoSSible Table of Contents Important Safety Instructions ............................................ 2 iNjuR y, ReaD TheSe iNSTR ucTioNS Package Contents ..........................................................3-4 caReFully beFoRe a TTemPTiNg Door Section Identification ................................................ 4 iNSTalla TioN. iF iN queSTioN Tools Required .................................................................. 5 abouT aNy oF The PRoceDuReS, Do Pre-In
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NoTe: DEPENDING ON ThE DOOR MODEL, SOME PARTS LISTED WILL NOT bE SUPPLIED IF NOT Package contents NECESSARY. REAR SUPPORTS MAY OR MAY NOT bE INCLUDED WITh YOUR DOOR. Stud plate (as required) Door sections (as required) Pull handles (2) horizontal Tracks with attached horizontal angle Rh/Lh (1) Torsion tube (1) Operator Asymmetrical u-bar bracket (as required) Long and short stem rollers Right and left hand 5/16” X 1-1/4” Clevis (2) Vertical Rh/Lh Right and left torsion End bearing bracket (
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Door Section identification hinges are always pre-attached at the top of each Tools Needed: section (except top section) and the hinges are Recommended tools Warning label stamped for identification (except double wide end from hinges), #1, #2, #3, and #4. See view below. The page 5 stamp identifies the stacking sequence of the section. Top section The sequence is always determined by #1 being the #4 bottom section to #4 being the highest intermediate section. See views to the right. I
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Tools Required Pencil Ratchet wrench Vice grips Gloves Power drill 3/8”, 7/16” Socket driver Safety glasses hammer Phillips head screw- 9/32”, 1/2”, 3/16” & 1/8” Drill 1/4”, 3/8”, 7/16”, 1/2” & 7/16”, 1/2” & 9/16” driver 9/16” Wrenches Socket bits Level Tape measure Vice clamps Sawhorse Flat tip screwdriver 1/4” Torx bit Approved winding bars Step ladder Removing an old Door P1 imPoRTaNT: COUNTERbALANCE SPRING TENSION MUST ALWAYS bE RELEASED bEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXI
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backroom Suitable mounting surface 2” x 6” lumber minimum header board Preparing the opening 2” x 6” lumber P2 recommended Tools Needed: waRNiNg Recommended tools FAILURE TO SECURELY ATTACh A SUITAbLE MOUNTING PAD TO STRUCTURALLY SOUND FRAMING MEMbER COULD CAUSE SPRINGS TO from Door VIOLENTLY PULL MOUNTING PAD FROM WALL, RESULTING IN SEVERE Level header page 5 height OR FATAL INjURY. If you just removed your existing door or you are installing a new door, complete all steps in PREPARIN
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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). ST
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Pull handle installation 2 NoTe: For door section identification see page 4. bottom section Tools Needed: Tape Measure Locate and mark the horizontal and vertical center Pencil on the bottom rail of the bottom section, on single Power Drill car doors. 1/16” Drill bit Locate the 6” Max. Center the pull handle using the vertical and center 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 bo
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Counterbalance cable Long shaft roller counterbalance cables 3 bottom section imPoRTaNT: RIGhT AND LEFT hAND IS ALWAYS Double wide Tools Needed: DETERMINED FROM INSIDE ThE bUILDING LOOkING end hinges None OUT. 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. Rollers Uncoil the counterbalance cabl
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Vertical track vertical Track 5 Flagangle imPoRTaNT: ThE TOPS OF ThE VERTICAL TRACkS Tools Needed: MUST bE LEVEL FROM SIDE TO SIDE. IF ThE bOTTOM Roller bottom section 3/16” Drill bit SECTION WAS ShIMMED TO LEVEL IT. ThE VERTICAL Power Drill TRACk ON ThE ShIMMED SIDE, MUST bE RAISED 7/16” Socket Driver ThE hEIGhT OF ThE ShIM. Tape Measure 3/8” To 5/8” Position the left hand vertical track assembly over Level the rollers of the bottom section. Make sure the 5/16 X 1-5/8” Step Ladder coun
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Top section Top brackets 7 1st Top To install the L-shaped top brackets, align the top Set Tools Needed: bracket holes in the top bracket base with the second set of 2nd Power Drill base holes in the endcap of the top section. Set 7/16” Socket Driver Fasten using (4) 1/4” - 14 x 5/8” self tapping screws. Phillips head Secure the top bracket slide to the bracket base Screwdriver loosely using (2) 1/4” - 20 x 5/8” carriage bolts and Top (2) 1/4” - 20 flanged hex nuts. bracket base F
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adjustable operator bracket installation 9 U-bar imPoRTaNT! WhEN CONNECTING A TROLLEY Tools Needed: TYPE GARAGE DOOR OPENER TO ThIS DOOR, A Power Drill WAYNE-DALTON OPENER/TROLLEY bRACkET MUST Center line of top Adjustable operator bracket bE SECURELY ATTAChED TO ThE TOP SECTION 7/16” Socket Driver section (Top half) OF ThE DOOR, ALONG WITh ANY U-bARS PRO- 7/16” Wrench VIDED WITh ThE DOOR. ThE INSTALLATION OF ThE OPENER MUST bE ACCORDING TO MANUFACTURER’S Align center of both end tabs I
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Top Section 10 Place the top section in the opening and vertically Tools Needed: Door width align with lower sections. hammer +3-3/8” to 3-1/2” Tape Measure Temporarily secure the top section by driving a nail in Power Drill the header near the center of the door and bending 7/16” Socket Driver it over the top section. Now flip up hinge leaf against Step Ladder section, fastening center hinges first, and end hinges last. (Refer to Step 6). ® When installing a door with a Torquemaster Plus
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attaching horizontal Track to adjustable Flagangles (2) 1/4” - 20 X 9/16” 11 Track bolts Flagangle To install horizontal track, place the curved end over Tools Needed: the top roller. Align the bottom of the horizontal track 9/16” Socket with the vertical track. hand tighten the horizontal Ratchet Wrench track to the flagangle with (2) 1/4”-20 x 9/16” track 9/16” Wrench bolts and (2) 1/4”-20 flange hex nuts. Level 7/16” Socket Step Ladder waRNiNg DO NOT RAISE DOOR UNTIL hORIzONTAL TRACkS
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RIGhT hAND END LEFT hAND END bEARING bEARING bRACkET bRACkET Torsion end bearing brackets 13 Tools Needed: End bearing brackets are right and left hand. break the end bearing brackets Step Ladder apart. UPPER SLOTS Power Drill Starting on the left hand side and using USED ON 15” bREAk the upper slots in the end bearing Ratchet Wrench RADIUS TRACk. ThE END bracket, position above the flagangle LOWER SLOTS bEARING 7/16” Socket ON 12” RADIUS and secure the end bearing bracket to bRACk
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Right hand cable Torsion Spring assembly drum black 15 imPoRTaNT: RIGhT AND LEFT hAND IS ALWAYS Tools Needed: DETERMINED FROM INSIDE ThE bUILDING LOOkING Step Ladder 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. Left Torsion hand tube Facing the inside of the door, lay the torsion tube on cable the floor. Lay the spring with the black c
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Torsion spring Nylon center bushing 16 Center bearing Stationary spring Slide the nylon center bushing into the stationary Tools Needed: cone bracket spring cone at the end of the spring and align the Step Ladder stationary spring cone(s) with the holes in the center 9/16” Socket bearing bracket. Secure the spring(s) to the center Stationary spring Ratchet Wrench bearing bracket with (2) 3/8”-16 x 1-1/2” hex head cone 9/16” Wrench bolts and 3/8”-16 nuts. Step Ladder Torsion Nylon sprin
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Securing Door for Spring winding 18 Place vice clamps onto both vertical tracks just Tools Needed: above the third roller. This is to prevent the garage (2) Vice Clamps 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 INj URY. imPoRTaNT: DO NOT USE IMPACT GUN TO WIND SPRING(S). Place vice clamps above 3rd roller Track Vice clamps attached to inner rail of track winding
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winding Torsion Spring(s) continued... Carefully remove winding bar from winding cone. Tools Needed: 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. Adjustments to the required from the number of Set turns stated ma
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horizontal track Rear Support continued... Door edges 3/4” To 3/4” To 7/8” 7/8” imPoRTaNT: DO NOT SUPPORT ThE WEIGhT OF ThE Tools Needed: 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. Adjust w
