Wayne-Dalton 6100 Lift Cable Adjustments, Winding Springs, Securing Drum Wraps

Vice clamps above third track roller on both sides of door

Vice clamps attached to inner and outer rail of vertical track

Bottom section

NOTE: Single spring applications require no spring winding on the left hand side, but lift cable tension needs to be adjusted.

IMPORTANT: Counterbalance lift cable tension must be equal on both sides prior to fully winding springs.

See the Winding Spring Turn Chart for the required number of winding turns: For single spring applications:

Return to the right hand end bracket and continue winding the spring to the required number of turns for your door. Place pawl knob in lower position.

For double spring applications:

Either use the black tooth on the ratchet wheel for winding reference or place a mark on the winding shaft and end bracket. Place the ratchet wrench with 5/8” socket and a 3” extension onto the left hand winding shaft end. To wind the spring, rotate the winding shaft clockwise, while watching the black tooth on the ratchet wheel or the mark on the winding shaft. Rotate the winding shaft to the required number of winding turns for your door. Then return to the right hand side and wind the right hand spring to the required number of turns. Place pawl knob in lower position on both sides.

Important: Mark the number of spring turns onto the end bracket warning tag.

Note: Since total turns to balance door can deviate from winding spring turn chart values by ± 1/2 turn, adjustments to the recommended number of turns may be required after rear back hangs are installed.

Lift Cable Adjustments

25 Tools: Locking pliers, Flat tip screwdriver, Step ladder, Tape measure, Pliers/ Wire cutters

Starting on the right side, adjust the cable drum assembly by rotating the drum until the set screw faces directly away from the header. The position of the cam peak on the TorqueMas- ter® spring tube should be pointing straight up.

Loosen the set screw no more than 1/2 turn. Ensure counterbalance lift cable is aligned and seated in the first and second grooves of the cable drum. Pull on the end of the cable to remove all cable slack.

Snug the set screw and then tighten an additional 1-1/2 turns. Measure approximately 6” of cable and cut off excess cable. Insert end of the cable into the hole of cable drum. Repeat for left hand cable drum assembly.

IMPORTANT: Ensure the counterbalance lift cable is aligned and seated in the first and second grooves of the cable drum prior to winding springs.

NOTE: Illustration shows the right hand cable drum assembly, left hand cable drum assembly is symmetrically opposite.

	First and
	second grooves
	Cam peak
	pointing straight up
	Cut cable here
TorqueMaster®		Set screw
	6”
spring tube
	Insert
	cable here	Counterbalance
		lift cable
26	Winding Springs
	Tools: Ratchet wrench, 5/8” Socket, 3” Socket extension, Pliers/ Wire
	cutters, Flat tip screwdriver, Step ladder

WARNING

It is recommended that leather gloves be worn while winding springs. Failure to wear gloves may cause injury to hands.

Double check to ensure the counterbalance lift cable is aligned in the first and second grooves of the cable drum, see step Lift Cable Adjustments. There are two methods for counting the spring turns as you wind. One method is to identify the black tooth on the ratchet wheel inside of the end bracket. When the wheel makes one revolution and the tooth returns to its starting point, one turn has been made. The other method is to make a mark on the winding shaft (or socket) and end bracket, and count your turns in this manner.

Starting on the right hand side, turn the pawl knob on the end bracket to the upper position. Using a ratchet wrench with a 5/8” socket and a 3” extension, wind the spring by rotating the winding shaft counter clockwise, while watching either the black tooth on the ratchet wheel or the mark on the winding shaft.

NOTE: A 3” extension is recommended for added clearance from the horizontal track angle.

IMPORTANT: Pawl knob must be in upper position to add / remove required number of spring turns.

After 2 to 3 turns, remove the ratchet wrench and adjust the counterbalance lift cable on the left side. Ensure counterbalance lift cables are in the first and second grooves of the cable drums, as shown in step Lift Cable Adjustments.

End bracket
Marks			Pawl knob in
		Ratchet	lower position
	5/8”	wrench
Winding	Socket
shaft
Black tooth
on ratchet			Pawl knob in
wheel			upper position
Mark the number of		3”
spring turns onto the
		Extension
end bracket warning tag
WINDING SPRING TURN CHART
DOOR HEIGHT		SPRING TURNS
6’-0”		14
6’-3”		14-1/2
6’-5”		15
6’-6”		15
6’-8”		15-1/2
6’-9”		15-1/2
7’-0”		16
7’-3”		16-1/2
7’-6”		17
7’-9”		17-1/2
8’-0”		18

27	Securing Drum Wraps
	Tools: Step ladder

NOTE: If you don’t have drum wraps, then skip this step. Refer to Package Contents / Parts Breakdown, to determine if you have drum wraps.

Starting on the left hand side, position the left hand drum wrap, as shown. Slide the left hand drum wrap over the cable drum assembly.

IMPORTANT: Pull the counterbalance lift cable away from the header to clear the latch, while simultaneously sliding the drum wrap against the last rib until the three catches engage the 3rd rib.

Secure the hinge latch by rotating upward until a distinct snap is felt. Confirm the catch is fully engaged by lightly tugging on it. Repeat the same process for right hand side.

12

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