Wayne-Dalton 6100 User Manual

6100 Light Commercial Door

Torsion Spring

Installation Instructions and Owner’s Manual

IMPORTANT NOTICE!

Read these instructions carefully before

Wayne-Dalton Corp.
P.O. Box 67
Mt. Hope, OH 44660
www.wayne-dalton.com

Copyright 2009 Wayne-Dalton Corp. Part No. 333884 REV2 08/03/2009

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.

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 ..................................... 6

WARNING

TO AVOID POSSIBLE
INJURY, 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

Installation ..................................................................7-20

TECHNICIAN DO THE INSTALLATION
OR REPAIRS.

Optional Installations .................................................20-22

Side Lock .......................................................21

Pull Rope ........................................................21

Trolley Operator .............................................. 22

Maintenance ..............................................................22-23

Cleaning ......................................................... 22

Painting Instructions ....................................... 23

Dealer Locator Information.............................................. 23

Warranty ......................................................................... 24

Definition of key words used in this manual:

WARNING

INDICATES A POTENTIALLY HAZARDOUS
SITUATION WHICH, IF NOT AVOIDED, COULD
RESULT IN SEVERE OR FATAL INJURY.

CAUTION: PROPERTY DAMAGE OR INJURY CAN RESULT
FROM FAILURE TO FOLLOW INSTRUCTIONS.

IMPORTANT: REQUIRED STEP FOR SAFE AND PROPER
DOOR OPERATION.

NOTE: Information assuring proper installation of the door.

2

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1. READ AND FOLLOW ALL INSTALLATION INSTRUCTIONS.

2. Wear protective gloves during installation to avoid possible cuts from
sharp metal edges.

3. It is always recommended to wear eye protection when using tools,
otherwise eye injury could result.

4. Avoid installing your new door on windy days. Door could fall during
the installation causing severe or fatal injury.

5. Doors 12’- 0” wide and 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 damaged,
immediately have necessary adjustments and/or repairs made
by a trained door system technician using proper tools and
instructions.

8. DO NOT stand or walk under a moving door, or permit anybody to
stand or walk under an electrically operated door.

9. DO NOT place fingers or hands into open section joints when closing a
door. Use lift handles/gripping points when operating door manually.

10. DO NOT permit children to operate garage door or door controls.
Severe or fatal injury could result, should the child become entrapped
between the door and the floor.

11. Due to constant extreme spring tension, DO NOT attempt any
adjustment, repair or alteration to any part of the door, especially
to springs, spring brackets, bottom corner brackets, red colored
fasteners, cables or supports. To avoid possible severe or fatal injury,
have any such work performed by a trained door systems technician
using proper tools and instructions.

12. On electrically operated doors, pull down ropes must be removed and
locks must be removed or made inoperative in the open (unlocked)
position.

13. Top section of door may need to be reinforced when attaching
an electric opener. Check door and/or opener manufacturer’s
instructions.

14. VISUALLY inspect door and hardware monthly for worn and or broken
parts. Check to ensure door operates freely.

15. Test electric opener’s safety features monthly, following opener
manufacturer’s instructions.

16. NEVER hang tools, bicycles, hoses, clothing or anything else from
horizontal tracks. Track systems are not intended or designed to
support extra weight.

16. Avoid installing your door in close proximity to any heat source that
may exceed 200°F. Failure to due so, may cause door sections to
blister or warp.

After installation is complete, fasten this manual near
garage door.

Stud plate (as required)

Pull handles

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 sections (as required)

(2) Horizontal Tracks with attached horizontal angle RH/LH

Asymmetrical u-bar

(as required)

Long and short stem rollers

(as required)

Top bracket bases

(as required)

#6 Screw eye and pull rope

(If included)

(1) Operator

bracket

End bearing bracket

Top bracket slides

(as required)

(1) Center bracket

Right and left torsion
springs (as required)

Right and left

counterbalance cables

1/4”- 20 Flange hex nuts

(as required)

(1) Center bracket

bushing

3/8”- 16 Hex nuts

(as required)

(1) Torsion tube

Right and left hand

cable drums

Weather seal and nails

(If included)

1/4”-14 X 5/8” Self tapping

screw (as required)

5/16” X 1-1/4” Clevis

pin & cotter pin

Lift handles

#8 X 1 21/32” Quadrex pan

head screw (As required)

(2) Vertical RH/LH

Tracks

1/4”-20 X 11/16” Self drilling

screws (as required)

5/16” X 1-5/8” Hex head lag screws

(as required)

3/8”-16 X 3/4” Truss

head bolts (as required)

1/4”-20 X 9/16” Track

bolts (as required)

5/16” X 1-5/8” Tamper-resistant hex head lag

screws (as required)

Carriage bolts (as required)

1/4” - 20 X 5/8”

3/8”-16 X 1-1/2” Hex head bolts

(as required)

5/16” X 2” Tamper-resistant hex head lag

screws (as required)

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

3

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. If the stamp on the
end hinge is illegible, or double wide end hinges are
installed, refer to the section side view illustration to
the right.

NOTE: The section side view illustration shows the
end hinge profile of all the sections, and can also be
used in conjunction with identifying each sections.

The BOTTOM SECTION can be identified by #1 end
hinges, the factory attached astragal, and by the
bottom bracket warning labels on each end stile. This
section is always the 1st section from the bottom of
the door.

The LOCK SECTION can be identified by #2 end
hinges. This section is always the 2nd section from
the bottom of the door.

The INTERMEDIATE I SECTION can be identified by
#3 end hinges. Sections will have a warning label
attached to either the left or the right end stile of the
section. This section is always the 3rd section from
the bottom of the door.

The INTERMEDIATE II SECTION can be identified by
#4 end hinges. This section if always the 4th section
from the bottom of the door.

Warning label

Top section

#4

Intermediate II section

#3

Warning label

Intermediate I section

#2

Lock section

#1

Bottom bracket warning labels

Astragal

Bottom section

The TOP SECTION can be identified with no pre­installed end or center hinges on the section and the
warning label attached in the upper middle of the
section.

Hinge
stamping
location

TYPICAL HINGE STAMPING LOCATION

#1 End
hinge

Bot.

Bottom
bracket

Astragal

Door

Bottom

Height

9’0” 23.8” 20.8” 20.8” 20.8” 20.8”

SECTION SIDE VIEW

#2 End
hinge

Lock

STACK HEIGHTS

Lock

1 3/8”

#3 End
hinge

Int.

Intermediate

(third)

1 1/8”7/8”

(second)

1 5/8”

#4 End
hinge

Int.#2

Intermediate

II (fourth)

4

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local yellow pages/business listings or go to the Find a Dealer section online at www.wayne-dalton.com

Top

Tools Required

Power drill

Phillips head screw-

driver

Sawhorse

P1

Pencil

7/16”, 1/2” & 9/16”

Socket

Flat tip screwdriver

9/32”, 1/2”, 3/16” & 1/8” Drill

Ratchet wrench

bits

Removing An Old Door

Vice grips

Safety glasses

Tape measureLevel Vice clamps

1/4” Torx bit

3/8”, 7/16” Socket driver

1/4”, 3/8”, 7/16”, 1/2” &

9/16” Wrenches

Approved winding bars

Gloves

PRE-INSTALLATIONPRE-INSTALLATION

Hammer

Step ladder

IMPORTANT: COUNTERBALANCE SPRING TENSION MUST ALWAYS BE RELEASED BEFORE ANY ATTEMPT IS MADE TO START REMOVING AN EXISTING DOOR.

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 /Preparing the Opening”. These instructions are available at no charge from Wayne­Dalton Corp., P.O. Box 67, Mt. hope, Oh 44660, or at www.wayne-dalton.com.

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

5

P2

Tools Needed:

Recommended tools

from

page 5

Preparing the Opening

WARNING

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.

To ensure secure mounting of track brackets, side and center
bearing 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 14” (356 mm) above the
top of the opening for Torsion spring applications. For low 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 EXISTING JAMBS, HEADER AND
MOUNTING SURFACE. ANY WOOD FOUND NOT TO BE SOUND, MUST BE
REPLACED.

For Torsion spring applications, a suitable mounting surface must
be firmly attached to the wall, above the header at the center
of the opening. The mounting surface must be 2” x 6” lumber
minimum (Select southern yellow pine lumber. Do not use lumber
marked as spruce-pine-fur or SPF). The mounting surface must be
securely attached to the wall with four (4) 3/8” anchors for masonry
constructions or four (4) 5/16” x 4” lag screws for wood construction.

NOTE: Drill a 3/16” pilot hole in the mounting surface to avoid splitting
the lumber. Do not attach the mounting surface with nails.

Header board
2” x 6” lumber
recommended

Plumb jambs

Header

Jamb

Level header

Door
width

Headroom

Weather seal

Suitable mounting surface
2” x 6” lumber minimum

Door
height

Backroom

Jamb

Weather Seal (May Not Be Included):

Cut the weather seal if necessary to fit the header and jambs.

Align the header seal with the inside edge of the header and
temporarily secure it to the header with equally spaced nails. Next,
fit the jamb seals up tight against the header seal and flush with the
inside edge of the jamb. Temporarily secure the jamb seals with equally
space nails approximately 12” to 18” apart. This will keep the bottom
section from falling out of the opening during installation.

NOTE: Do not permanently attach weather seal to the jamb at this time.

HEADROOM REQUIREMENT: Headroom is defined as the space needed

above the top of the door for tracks, springs, etc. to allow the door to
open properly. If the door is to be motor operated, 2-1/2” (64 mm) of
additional headroom is required.

BACKROOM REQUIREMENT: Backroom is defined as the distance
needed from the opening back into the garage to allow the door to
open fully.

Jamb

Weather Seal

HEADROOM REQUIREMENT

Track type Torsion springs

12” Radius track 12 1/2”

15” Radius track 14-1/2”

BACKROOM REQUIREMENT

DOOR HEIGHT TRACK

9’0” 12”, 15” Radius 126” 168”

MANUAL

LIFT

Weather

seal

MOTOR

OPERATED

6

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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). STAINLESS STEEL OR PT 2000 COATED LAG
SCREWS ARE NOT NECESSARY WHEN INSTALLING PRODUCTS ON UN-TREATED LUMBER.
IMPORTANT: WHEN INSTALLING 5/16” DIAMETER LAG SCREWS USING AN ELECTRIC DRILL/DRIVER, THE DRILL/DRIVER’S CLUTCH MUST BE SET TO DELIVER NO MORE THAN
200 IN. LBS. OF TORQUE. FASTENER FAILURE COULD OCCUR AT A HIGHER SETTING.
NOTE: It is recommended that 5/16” lag screws be pilot drilled using a 3/16” drill bit, prior to fastening.

1

Tools Needed:

Tape Measure

Pencil

Power Drill

1/16” Drill Bit

Lift Handle Installation

NOTE: For door section identification see page 4.

NOTE: Use reference illustrations below for lift

handles positions on singles and double car garage.

Measure the width of the center stile which will
receive the lift handle(s). Divide that measurement
in half and mark a vertical line on the center of the
stile.

If you are installing two lift handles on the stile,
you will need to measure from the edge of the
center stile to the center line mark. Divide that
measurement in half and draw a second and third
vertical line parallel to the previously 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 intersecting line(s) and
mark another horizontal line.

Use the point(s) where the top horizontal line
intersects the vertical line(s) to locate the top hole of
the lift handle(s).

Using the lift handle as a template, mark this
location on the stile. Keeping the carriage handle
aligned on the vertical line, mark the lower carriage
handle hole on the stile.

Lock section

center stile

Locate the center

SINGLE WIDE DOORS

3-7/8”

Horizontal line

DOUBLE WIDE DOORS

Lift

handles

#10 X 5/8” pan head

self tapping screws

Locate the

centers

INSTALLATION

Drill a 1/16” pilot hole, then fasten both lift handles
using #10 X 5/8” pan head self tapping screws.

If the door came with two sets of lift handles repeat
process.

Lift handle placement reference on single wide doors

20” Min. To 30” max.

Lift handle placement reference on double wide doors

20” Min. To

30” max.

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7

2

Pull Handle Installation

Tools Needed:

Tape Measure

Pencil

Power Drill

1/16” Drill Bit

NOTE: For door section identification see page 4.

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. Drill a 1/16”
pilot hole, then fasten pull handles using (2) #10 X
5/8” pan head self tapping screws.

If the door came with two pull handles, locate them
directly below the lift handles and repeat installation
process.

Use reference illustrations below for lift handles
positions on singles and double car garage doors.

Bottom section

Bottom section

Locate the

center

6” Max.

Pull handle

(2) #10 X 5/8” Pan

head self tapping

screws

20” Min. To

30” max.

Pull handle placement reference on single wide doors

20” Min. To 30” max.

Pull handle placement reference on double wide doors

8

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