Assa Abloy Corbin Russwin ED5860 Series User manual

Installation Instructions
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
WARNING
This product can expose you to lead
which is known to the state of California
to cause cancer and birth defects or other
reproductive harm. For more information
go to www.P65warnings.ca.gov.
ED5860 (B) Series
Concealed Vertical Rod
Exit Device

2
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
TOC Table of Contents
1 Package Contents ...............................................................3
2 Options .........................................................................4
3 Dogging .........................................................................4
4 Plastic Installation Template .....................................................5
5 Pre-Installation ..................................................................6
a To Change Hands ................................................................6
b Check Before Starting............................................................6
c Mark Door.......................................................................7
d Prepare Door, Frame and Sill.....................................................8
e Size Device ......................................................................8
6 Installation ......................................................................9
a Rod Assembly and Preliminary Adjustment ......................................9
b Install Rods .................................................................... 10
c Install Device .................................................................. 10
d Install Strikes .................................................................. 11
e Complete Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 Maintenance .................................................................. 14

3
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
1 Package Contents
Top Strike
Top Latch
Top Tube
(5) Cotter Pin
8' (2.44m) Opening
7'6"(2.29m) Opening
7'2"(2.18m) Opening
7' (2.13m) Opening
Top Rod
(2) Arm and Bracket Assembly
(2) Yoke Pin
Hole Plug (Fire
Devices)
Dogging Key
(2) E-Rings
(2) #8-32 x 2"PHPMS Temporary Screws
(2) Set Screw
#8-32 UNC
Bottom
Rod
Assembly
Cover
(2) 8-32 x 5/16"PUFHMS
Deadbolt
Bottom Bolt Case
(6) 10-24 x 1/2"PFHMS
Strike
End Clamp (3) 8-32 x
5/16"
PUFHMS
End Cap
(2) 1/4-20 x 1"PRHMS
(2) 10-32 x 3/8"PUFHMS or (2) 10 x 1"PFHWS
(6) 10-24 x 1/2"PFHMS
Figure1
(2) 1/4-20 x 1"PRHMS
(Special Head)

4
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
2 Options
1/4-20 Sex Nut Option:
• Standard for Fire Rated doors.
• Recommended for wood and unreinforced metal doors.
Device Quantity Size
All (No Trim) 4
1/4-20
All (With Trim) 2
Rod Extension Option:
2"(51 mm)
6"(152 mm)
12"(305 mm)
3 Dogging
Dogging is a feature that holds bolts in a retracted position with the touchpad depressed for push-pull
door operation.
Note:
Dogging is not a feature of fire-labeled devices.
To Dog Device:
1. Insert dogging key.
2. Depress and hold the touchbar.
3. Turn key 1/4 turn clockwise.
Important:
Device is packed ready for any compatible trim.

5
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
4 Plastic Installation Template
For use in conjunction with instruction sheets packed with exit device.
Holes and slots are identified below by exit device series and trim. Prep door and frame for only those
features required for the exit device being installed.
Template
Concealed Vertical Rod
All ED5000 Series Devices
Against Frame Stop or Mullion
(when applicable)
For Rim and SecureBolt®Exit Devices Only
Rim and
SecureBolt®
Mortise
ED5200S
Concealed Vertical Rod
All ED5000 Series Devices
Vertical Reference
Trim Only
Horizontal
Reference
Trim Only
Against Door
Surface
Trim Only
Vertical Reference
Door
Frame
Door Stop
Figure2

6
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
5 Pre-Installation
a To Change Hands
1. Remove four (4) screws and
vertical lifter assembly.
2. Rotate device 180˚ to
opposite orientation.
3. Insert vertical lifter assembly and
reinstall screws.
Note:
Lifter must fit under lift block as
shown. (Figure3)
b Check Before Starting
Doors and frames with walls having a structural
thickness (metal skin plus reinforcement) to
engage less than three (3) full screw threads are
considered unreinforced.
Unreinforced Doors:
Use SNB (sex nuts and bolts) or Blind Rivet Nuts.
(Figure4)
Unreinforced Frames:
Use Blind Rivet Nuts. (Figure5)
Recommended fasteners for unreinforced
openings may not be supplied by Corbin Russwin.
• Door must swing freely.
• Door must not be warped.
• Door must not bind.
• Door must not sag.
Blind Rivet Nut
Door Skin
Reinforcement
Figure4
Figure5
• Minimum Door
Stile: 4-1/2"
(114mm)
• Door and frame
must meet
structural and
dimensional
specifications
on exit device
template(s) for
door and frame
preparation.
• Device must seat
flush on door
surface. To clear
raised molding,
consult the
factory.
Figure3
RHR Device
RHR Door
LHR Device
LHR Door
Lift Block
Vertical Lifter Assembly Vertical Lifter Assembly
(4) 8-32 x 3/16"PRHMS (4) 8-32 x 3/16"PRHMS

7
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
5 Pre-Installation (continued)
c Mark Door
Single Door or Pair without Mullion:
• Locate and mark horizontal and vertical
centerlines as shown. (Figure6)
• LHR door shown. Preparation is typical for
both door hands. (Figure 6)
Caution:
If device is mounted higher or lower than shown,
rod length must change. Lengthen or cut top
and bottom rods as shown in "Rod Assembly and
Preliminary Adjustment"on page 9.
Note:
Bottom bolt will retract to 1/8"(3mm) above floor
strike. Floor covering in the door path must be laid
accordingly.
Figure6
LHR Door
Inside Face
Door
Door
Measure Gap
Write Dimension Here: _____
Centerline
Vertical
Reference
Centerline
Horizontal
Reference
39-15/16"
(1014")

8
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
5 Pre-Installation (continued)
d Prepare Door, Frame and Sill
1. Locate device paper template aligning
VERTICAL REFERENCE and HORIZONTAL
REFERENCE lines on door and template. Tape
template to door face. (Figure 7)
2. Extend centerline of rod and strikes from
device paper template to door top and
bottom, on door face.
3. Locate top strike and bottom strike templates,
aligned on centerline of rods and strikes on
door.
4. Tape templates in place and mark holes.
(Figure7)
Note:
Auxiliary door marker is included to verify
correct door preparation. Reinforced doors
and frames, with factory made cutouts, are
recommended.
5. Locate and tape trim template to door.
(See instructions packed with trim)
6. Mark and prepare holes per installation
template.
Device and Bolt Case Plates: Use two (2) 1/4-20
machine screws for metal reinforced doors OR
two (2) 3/8"(10) diameter sex nuts and bolts for each.
Top Strike: Use two (2) 10-24 machine screws.
Note:
Third screw MUST ONLY be used to lock strike in final position (See "Rod Assembly and Preliminary
Adjustment" Step 7).
Bottom Strike: 5/8"(16) diameter x 3/4"(19) deep hole.
e Size Device
Device must be field cut to size, unless standard
opening and device are 36"(0.91m). (Figure8)
LHR Door Open 90˚ Inside Face
C
L
Figure8
Align mounting holes in door
with mounting holes in device.
Align horizontal line on door
with edge of device.
Verify that there is
no gap between
end cover &
touch bar prior to
marking cutoff.
Mark cutoff line.
Cut square on line.
Figure7
Centerline Vertical
Reference
Centerline Rods &
Strikes
LHR Door Inside Face
Finished Floor
Centerline
Horizontal
Reference
Top Strike Template
(Mounts on Frame
Rabbet)
Floor Strike Tem-
plate (Mounts on
Finished Floor
Device Paper
Template

9
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
6 Installation
a Rod Assembly and Preliminary Adjustment
1. Remove door from opening.
2. Set flat; device side up. Do not hang door until
you "Complete Installation"on page 12.
(Figure12-A)
3. Set length of top rod assembly. See Detail 1 -
Figure9; Figure12-B.
4. Connect top and bottom rods to arm/bracket
assemblies using two (2) cotter pins each.
(Figure12-C)
5. Align rod setup gauge over device cutouts and
centerlines. (Figure12-D)
6. Tape gauge to door face.
7. Connect top latch to rod assembly. Latchbolt
must be fully extended. See Detail 2 -
Figure10; Figure12-E.
8. Set top latch assembly in place on door.
Maintain 1/8" (3) location from top of door as
shown. (Figure12-F)
9. Align yoke pin holes in arm and bracket
assembly with alignment hole in rod setup
gauge. (Figure12-G)
10. Adjust top latch and rod assembly for proper
alignment.
11. Thread deadbolt into bottom rod assembly.
Set bottom rod assembly in place on door.
(Figure12-H)
12. Align yoke pin hole in bottom arm and
bracket assembly with alignment hole in rod
setup gauge.
13. Adjust bottom bolt for proper length.
Detail 1
Figure9
8'
(2.4 M)
7'
(2.13 M)
4"
(102)
6'8"(2.03 M)
(FIELD DRILL)
Adjust Top Rod
Cotter Pin
Tube
7'6"
(2.29 M)
7'2"
(2.18 M)
Detail 2
Latchbolt Extended
(Correct Assembly)
Latchbolt Retracted
(Incorrect Assembly)
Figure10
Detail 3
Bottom Rod Assembly
Bolt fully extended
(Pin toward top of door)
Figure11
NOTE:
Be certain bottom bolt is fully extended. See Detail 3 - Figure11.
Yoke Pin
Holes
Centerline of
Device Mounting
Holes and Rods
Gap* + 3/8 (10)
(*From Step 1)
1/8
(3)
(Hold)
Detail 2 Detail 1
4 Free Threads
(Typ. Ref.)
Detail 3
Rod Setup Gauge FM169
Figure12
FG
G
DH
E
G H
H
H
A
C
B
C

10
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
6 Installation (continued)
b Install Rods
1. Slide rod assemblies into door. (Figure14-A)
2. Attach top latch with six (6) #10-24 X 1/2"
PFHMS. (Figure14-B)
3. Install bottom bolt case with six (6) #10-24 X
1/2"PFHMS. (Figure14-C)
4. Thread set screw into yoke pins (Insert with
hex socket end inside pin).
5. Thread #8-32 x 2"PHPMS screws into slotted
end of yoke pins, until seated to hex head set
screw. See Detail 1 - Figure13.
6. Install two (2) yoke pin assemblies into arm
and bracket assemblies. (Figure14-E)
Detail 1
Figure13
1/4"
(6.4) Yoke Pin
E-ring Groove
Set Screw
#8-32 PHPMS
Temporary Screws
Figure14
A
E
B
C
c Install Device
1. Mount trim when required. (Follow
instructions packed with trim.)
2. Seat device in place. (Figure15-B)
3. Connect device to arm and bracket assemblies
using temporary screws to position yoke pins
in latch head.
4. Install e-ring into yoke pin grooves.
5. Fasten device latch head using two (2) 1/4-
20 PRHMS or 3/8"(10) dia. SNB. (Figure16)
Remove temporary screws.
Note:
Be certain to retighten yoke pins after removal
of temporary screws.
6. Center end of device on horizontal reference
line of door.
7. Using end clamp as a template, locate end
clamp mounting holes.
8. Prepare end clamp holes and mount end
clamp using two (2) 1/4-20 PRHMS or
3/8"(10) SNB. (Figure15-F)
C
L
Figure15
BF
C
Detail 1
Device
End
Clamp
1/2
(13)
1-1/4
(32)
Horizontal Ref.
Centerline
Device Screws
(Bolt to door reinforcement,
sex nuts, or trim studs)
Figure16
E-Ring
Yoke Pin

11
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
6 Installation (continued)
d Install Strikes
Figure17
X
Y
Centerline of Device Mounting Holes,
Rods & Strikes
Detail X:
Figure18
Top Strike
(2) 10-32 x 3/8"PFHMS
or (2) 10 x 1"PFHW
Detail Y:
Strike
(Press in place)
Figure19
Note:
Bottom bolt will retract to 1/8"(3mm) above floor
strike. Floor covering in door path must be laid out
accordingly.

12
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
6 Installation (continued)
e Complete Installation
1. Rehang door plumb and true to opening.
2. Set strike roller between tripping lever and
bolt. DO NOT PRELOAD BOLT. (Figure20)
Note:
Rods should move freely inside door. Bolts
extend automatically and should deadlock
when door closes and tripping lever hits
frame. Top bolt should retract flat. Bottom bolt
should travel 1/2"(13 mm) and engage
3/8"(9.5 mm) into strike in down position
without dragging on floor surface in up
position.
3. Test device action by touchbar, by trim, and by
dogging. Adjust as needed.
4. Adjust rod for proper bolt throw:
a. Use 3/32" (2.4 mm) hex wrench to remove
set screws B1 and B2. (Figure 20)
b. Adjust top rod first with adjusting screw
C1. (Figure 20)
c. With device in dogged position (panic
devices) or touchbar fully depressed
(fire devices), adjust top rod so that top
latchbolt is flush and hold back feature is
engaged.
d. Lengthen top rod an additional 1/2 turn
for proper latchbolt positioning.
Note:
• If adjusting screws bottom out
before proper device operation,
door and device must be removed so
larger adjustments may be made by
threading rod in or out, or by moving
cotter pin to different hole in rod.
• To avoid thread damage and provide
positive locking, be sure set screws
engage flats on adjusting screws.
Figure20
B1
C1
B2
A
Cover
Screw
Hole
Top Adjusting Screw
Longer (CW)
Shorter (CCW)
Top Rod
Shim
Bolt
Strike
Roller
Tripping
Lever

13
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
6 Installation (continued)
e Complete Installation (continued)
e. Adjust bottom rod with adjusting screw
C2. (Figure21)
f. With top latch retracted in hold back
position, and touchbar dogged or fully
depressed, adjust bottom rod so that
deadbolt clears strike by 1/16"(1.6 mm).
The bottom rod should be in position in
active case with square head of connector
hanging in the guide.
g. Check device operation by opening and
closing the door. An additional minor
adjustment may be required for full
retraction and correct strike engagement.
Top latch should consistently go into
holdback with gentle (full) press of
touchbar.
Note:
To avoid thread damage and provide
positive locking, be sure set screws engage
flats on adjusting screws.
5. After acceptable device function, install third
screw in top strike to lock strike in position
with 10-24 x 3/4" PFHMS.
6. Install device cover and end cap with (2) 8-32
PFHMS each.
Figure21
C2
Cover
Screw
Hole
3/8
(10) Bolt
Engagement
Bottom Adjusting Screw
Longer (CW)
Shorter (CCW)
Bottom Rod

14
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
7 Maintenance
• Periodically remove covers and coat mechanisms with an appropriate lubricant. This is particularly
essential in corrosive environments for proper product function.
• Check mounting fasteners periodically. Re-tighten if found loose. Apply threadlocking compound or
change part fasteners if screws continue to back out.
• Periodic checks (and adjustments) or rods may be required to compensate for changes in the
opening (e.g. door sagging).

15
ED5860 (B) Series
Installation Instructions
Exit Device
FM544 02/20
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole
or in part without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.

Corbin Russwin is a brand associated with ASSA ABLOY Access and Egress Hardware Group, Inc., an ASSA ABLOY Group company.
Copyright © 1998, 2020 ASSA ABLOY Access and Egress Hardware Group, Inc. All rights reserved. Reproduction in whole or in part
without the express written permission of ASSA ABLOY Access and Egress Hardware Group, Inc. is prohibited.
For installation assistance contact Corbin Russwin
1-800-543-3658 • [e-mail]
Corbin Russwin, Inc.
225 Episcopal Road
Berlin, CT 06037 USA
Phone: [phone]
Fax: [phone]
www.corbinrusswin.com
FM544 02/20