Overhead door 55 Assembly instructions

MODEL 55
GARAGE DOOR OPENER SYSTEM
12-15-81
M - 104348
ASSEMBLY, INSTALLATION
AND
OPERATING INSTRUCTIONS
---
.- --
-- ------ -- -- · --- ---
INST ALLA Tl ON KIT NOT INCLUDED.
Printed in U.S.A. Page 1

TABLE OF CONTENTS
HOW TO USE THIS BOOK------- 2
TOOLS NEEDED 2
GENERAL NOTES 3
ASSEMBLY INSTRUCTIONS 4-9
ASSEMBLY DRAWING 9
INSTALLATION INSTRUCTIONS _____ 10-17
WIRING 18-20
OPERATION AND ADJUSTMENT 21
TROUBLE SHOOTING GUIDE 22
PARTS AND SERVICE 22
PARTS LIST _ _ _____ __ ____ 22
ILLUSTRATED PARTS BREAKDOWN 23
WIRING DIAGRAM 24
WIRING SCHEMATIC 24
TOOLS NEEDED
HOW TO USE
THIS BOOK
l. Use tools indicated by silhouettes
at top of instruction.
2. Perform the instruction according
to the words and iIlustration.
3. Put a check in box after completion
of instruction.
4. Proceed to next step.
Adjust drive chain-cable.
9 116 WRENCH
ADJU S TING
BOLT
ADJU S TABLE
EXAMPLE
HEADER PULL E Y
A
SS EMBLY
BOOM
You will need the tools shown below to assemble and install this operator.
ELECTRIC DRILL
6/32 BIT
1/4 BIT
-=- : . 0
CARPENTER
LEVEL
A
STEP LADDER
6-0
[.., ___ ~L\ HACK SAW
411 .......... D• ADJUST ABLE
""9 END WRENCH
Page 2
NEEDLE NOSE
PLIERS
" 0
-c
END WRENCH
•
TAPE MEASURE
7/16 & 9/16
•
STRAIGHT EDGE
SLOTTED
SCREWDRIVER
•
PENCIL
WIRE
•
POCKET KNIFE
CUTTERS
OR
WIRE STRIPPERS
PLIERS
n

GENERAL NOTES
The following procedures must be performed before operator can be ins ta I led. Failure to
complete
the following procedures can cause operator failure and/or hazardous conditions
which
could cause personal injury.
1. Check working condition of door. Door should operate freely without sticking or binding.
Lubricate door rollers and hinges with SAE 30 wt. oil. Replace damaged or broken
rollers and
hinges. Tighten all bolts and screws.
2. Check for broken counterbalance springs and worn or broken lift cables. Replace any
defective parts.
CAUTION
Repairs and adjustments to cables and springs can be hazardous
and should be performed
by qualified door service people.
3. Counterbalance should be set so that door does not have to be held up or down.
4. If door is equipped with a locking device, make it inoperative by permanently securing
the locking bar in an unlocked
position.
CAUTION
Remove any lift or pull rope if door is so equipped.
WARNING
DO NOT CONNECT ELECTRICAL POWER TO
UNIT UNTIL INSTRUCTED TO DO SO.
Page 3

ASSEMBLY
10
Lay powerhead and boom on workbench or
floor. Assemble boom (3 sections).
30
Position carriage over tapered end of boom~
BOOM
CARRIAGE
Page 4
LIMIT
•
SWITCH
CABLE
... _l
..............
...... __
20
Read and remove red "caution" tag from
cable o Thread cable through carriage o
40
Make sure cable
is positioned in
bottom
of groove.
Install boom into boom bracket.
BOOM BOOM
BRACKET
POWERHEAD
n

n
ASSE , MBLY
50
Insta 11 header pu 11 ey assembIy on end of boom •
70
HEADER
PULLEY
ASSEMBLY
Wind cable (counter-clockwise) into
spring end.
Make sure cable will
not pu 11 out of spring.
60
Insert cable stop into coil of spring.
\
\
Hook spring to header pu 11 ey assembI y.
Page 5

ASS E MBLY
90
Install cable dogs on limit switch cable.
i
rrJ: ..... "."'~.:~-~: " ~"~:......... .. .......
a·~ ~ 12·
.... FROM FROM
HEADER POWERHEAO
110
CABLE
DOG
LIMIT
SWITCH
CABLE
Wrap around drive sprocket and back through
support
bracket.
Page 6
100
Route cable end of drive chain-cable
through support bracket.
120
Pull cable through until chain has wrapped
drive sprocket and extends past front
of
powerhead six (6) inches.
SUPPORT
BRACKET
~~~~~-- DRIVE
SPROCKET
Make sure chain is seated in drive sprocket
and
idler pulley.
n

ASSEMBLY
130
Make sure chain is seated in drive sprocket
and idler pulleyo
150~
DRIVE
SPROCKET
Install retainer clips on connecting links.
A B C
0§) .lll\. @=ID
CONNECTING LINK
CHAIN
CABLE
ASSEMBLY
140
Insert carriage engagement cylinder into
carriageo Wrap cable end of drive chain-
cable around header pulley and back to
carriage o Connect chain and cable to car -
riage engagement cylinder using connect-
ing Iinks o
CONNECTING LINK
CHAIN
160 ~~_,.
Adjust drive chain-cable.
9/16 WRENCH
ADJUSTING
BOLT
ADJUSTABLE
END WRENCH
TO INCREASE TENSION
IMPORTANT
CHAIN CABLE
ASSEMBLY
1-
BOOM
HEADER PULLEY
ASSEMBLY
BOOM
With carriage near header end of boom,
chain should not sag below center line of
boom more than 3/4
11
•
Page 7

A SSE MBLY
170
Correctly installed : - Header pulley assembly.
-Limit switch
cable,
ADJUSTING
BOLT
ADJUSTING
NUT
190
- Cable dog.
HEADER PULLEY
ASSEMBLY
Remove cover (4 screws).
Page 8
180
Install gear guard.
200
Center limit switch actuator arm.
CABLE
DO G
Arm must be perpendicular (90°) to cable
and parallel with front of chassis.
n

n
ASS EMBLY
210
Re -ins ta II cover .
COVER
CIRCUIT BOARD
IMPORTANT
Make sure antenna is
fully extended through
hole .
ASSEMBLY ORAWING
C ONNECTING
LINKS
80 8 84 - 1
TEN S ION
S PRING
10 2 158-1
LIMIT SWITCH
C ABLE
10 40 98- 1
1040 96 - 2
CARRIA GE
220
CHECKLI ST
D He ad er pulley assembly is positioned
c
orr ec tly .
D Drive chain is sea ted in drive sprocket.
D Drive chain is not tw isted.
D Cable is seat ed in h eader pulley .
D Sensitivity cab le dogs ins ta Iled
securely .
T HREE PIECE
BOOM
104038- 1
104038- 2
~ !~~ ~ '.
I
SUPPOR T
BR A CKET
102106 - 1
DASH ONE (1) PART NUMBER FOR 7 FT. DOORS.
DASH TWO (2) PART NUMBER FOR 8 FT . DOORS.
Pa ge 9

INSTALLATION
230
Measure width of door to determine center.
tCENTERLINE OF DOOR
I~ Ii
......,.,_.-_...-, ~
,)
ATTACHMENT FOR DOOR BRACKET
FOR DOORS WITHOUT CENTER STILE
If header does not have suitable woodwork where
header bracket will be installed, then such will
have to be made. It is suggested that a wood
2
11
x6
11
be secured to nearby existing woodwork.
If door does not have a
center stile or suitable
attachment for attaching door bracket then
door must
be re-inforced with wood or steel
at mounting point.
250
-;, : 0
Raise door until top section reaches its highest
arc of travel. Mark header on center line at
point where level touches header.
Page 10
DOOR
OPENING
CARPENTERS LEVEL
-- ..
HIGH ARC OF
DOOR TRAVEL
DOOR TRACK
DOOR SECTIONS
240
Mark center line on door and header.
---------- CEl LING
HEADER ~
,LcENTERLINE
I OF DOOR
DOOR
260
Mark center line of header bracket
three (3) inches above high arc of
door troveI•
---------- CE Ill NG
HEADER ~
CENTERLINE OF LcENTERLINE
HEADER BRACKET I OF DOOR
HIGH ARC OF
DOOR TRAVEL
DOOR
'
I
n

INSTALLATION
270 280
Mark horizontal center line of header bracket. Position header bracket on center line and
mark mounting hole locations on
center line.
CEILING
HEADER
------------CEILING
------
HEADER
HEADER BRACKET
290P--- 3004)
Dri II 5/32
11
diameter holes at marked locations. Secure header bracket to header.
CEILING
HEADER
CENTER LINE· OF
HEADER BRACKEJ _ \\\
),"-
CENTER LINE I
OF DOOR
I
I
HEADER
1/4 X 1-3/4 -..-:.~ I
LAG SCREWS
HEADER
BRACKET
I
CENTER LINE --J
OF DOOR
CEILING
Page 11

INST ALLA Tl ON
a10 A
Rest header end of boom on top edge of top door section and powerhead on top of step ladder.
EXTENSION SPRING DOOR
OR
Rest header end of boom on torsion spring and powerhead on top of step ladder.
TORSION SPRING DOOR
Page 12
I
\

INSTA .LLATION
320
Attach header pulley assembly to header bracket.
CEILING
NUT 1 /4-20
340
To raise powerhead: raise door slowly.
PROTECTIVE
PAD
33D ':Jll4'_.,.
Secure header bracket bolt.
CEILING
HEADER
=
350
Continue raising door until fully open.
PROTECTIVE~~
--.9-------~i) .
POWERHEAD
LADDER
Page 13 ·

INST ALLA Tl ON
360
Position a wood 2x4 on edge between door
section and boom. Use center line of door
to correctly align boom.
¢ CENTER LINE
OF DOOR
DOOR
IN FULLY OPEN POSITION
380 [ L\
Subtract 2 inches from distance (A)
EXAMPLE
If dimension (A) equals 9- l/2 inches,
hanging brackets wi II have to be at least
7- l/2 inches long.
Count up 7 holes.
Cut angles 3/8 inch above 7th hole.
Notch lower end of angles.
Page 14
370
Measure distance from powerhead mounting
ho le
to cei I ing. Th is distance (A) wi 11
be used to determine length of hanging
brackets.
A
0 0
SECURE THIS END
TO CEILING ANGLE
•
~
~314•
"'-.__
•
SECURE THIS END
TO OPERATOR

INS.T ALLATION
390
1
Secure mounting angles to powerhead.
Locate ceiling joists•
LOCATE APPROXIMATE CEILING
ANGLE MOUNTING LOCATION USING
VERTICAL ANGLES AS A GUIDE
•
0
0
0
0
0
0
0
BOLT 1/4-20 x 1/2
W/LOCKNUT
410r
0 0
Drill 5/32
11
diameter pilot holes through
ceiling into ceiling joists at marked locations.
APPROXIMATE
MOUNTING
;?'~ ) ·~ POSITION
CEILING JOIST :\ \0 V
1
;\; ,,:
11, L
- - - - - 7i-:~ --:- - - - -
., .
'•1 '
-= ~ ~--- == _::: fu"[i-=. =::::. -=-=::::.::::.-=
,•
400
Hold ceiling angle in mounting position
and mark mounting hole locations using
appropriate holes in angle as a guide.
\
\ \
\ \
\ \
\
\ \
\ \
\ \
CEILING JOISTS \ \
\ \
\ \
\ \
\ \
Secure ceiling angle to ceiling using
1/4"x 1-3/4
11
Lag screws.
\
\ \
\ \
MOUNTING
\
\ \
\ \
\ ' ..
CEILING JOIST \
\ \
\ \
Page 15

INSTALLATION
Secure hanging angles to ceiling angle
tighten all bolts and nuts.
450r
Dri 11 1/4
11
diameter holes through door
at locations marked.
Page 16
If necessary raise door to
avoid drilling into header .
440
Hold drawbar bracket in mounting position
with
back of angle on center Iine of door.
Mark mounting hole locations.
t- CENTERLINE OF DOOR
460~
Secure drawbar bracket to door using
1/4"-20 x 2" carriage bolts.
DRAWBAR BRACKET
n

INS~TALLATION
470.,
Attach yokes to drawbar bracket. Tighten
locknut but do not compress yokes to
brack-
et. Yokes must move freely.
1/4-20 x 2
CARRIAGE BOLTS (2)
~
DRAWBAR
"'--~ YOKES (2)
DRAWBAR ~
14
NUTS <2>
BRACKET @l
104432-1 \ ~ 3/8-16 x 3/4
·~·~ BOLT
'¥!!..
3/ 8
@~ ~· ,• ';::,.. DRAWBAR
~- YOKES
LOCKNUT 76557
490
Route pul I cord through release lever.
Install pull knob on pull cord approximately
six
(6) feet from floor.
RELEASE LEVER
~
=
DRAWBAR
77089-1
480'
With carriage against header-end I im it switch
dog,
connect drawbar arm to carriage.
Align two (2) holes in drawbar arm with two
holes in drawbar yokes and
secure.
EMERGENCY
RELEASE
DECAL
0
0
0
0
Remove protective backing from EMERGEN-
CY
RELEASE decal and install on door, near
drawbar
bracket.
500
CHECKLIST
Header bracket secure.
D
D Door
bracket-yoke pivot bolt secure,
but not too tight.
D Header pulley assembly pivot
bolt secure
but not too
tight.
D Hanging bracket bolts tight.
D Drawbar to yoke bolts tight.
D Drive chain-cable is tight (tensioned
correctly).
D Carriage engagement cylinder is
engaged with carriage.
Page 17

WIRING
510
Separate end of push button wire.
530
Remove insulation.
Page 18
520
Carefully cut insulation around wire.
Do not cut wire.
••
Th is procedure is best performed
by using wire
strippers.
540
Twist ends of wire strands together.
n

n
)
WIRIN .G
550----
Shape wire leads like a hook, and
connect leads to operator terminaIs.
570
Insta 11 push button on wa 11 near house
entrance door approximately six (6) feet
from floor.
CAUTION DECAL
Button should be out
of reach of children.
~
§
a·-o·
Peel backing off
11
PUSH BUTTON -CAUTION
11
de ca I and att a ch to wa 11 near pushbutton.
560
Route push button wire from powerhead
along ceiling to house entrance door.
Staple wire as necessary to prevent
entanglement or contact with moving objects.
Shape wire leads like a hook, and
connect leads to push button terminals.
PUSH BUTTON
580
Depress ends of light lens to install
or remove lens.
IMPORTANT
USE MAXIMUM 75 WATT BULB.
Page 19

WIRING
590
WARNING
It is important that electrical power to operator be cut off when powerhead cover is
removed. Electrical power must remain disconnected while making electrica I con-
nections and limit switch cable adjuslments. Keep hands and objects clear of power-
head if electrical power is re- connected with cover off.
Operator is equipped with a factory installed
power cord and must be plugged into a 115 volt,
60 hertz, grounded electrical outlet.
CAUTION
For maximum safety it is essentiaI that
operator be properly grounded.
If a convenient electrical outlet has to be instal-
led it is recommended that such work be perform-
ed by a licensed electrician. Use of an extension
cord is NOT RECOMMENDED.
When
installing a convenient electrical outlet, it
is suggested that an electri ca I switch be insta Iled
to facilitate emergency power cutoff.
600
If local electrical codes require permanent
wiring, it is recommended that such work
be performed by a licensed electrician.
Remove cover (4 screws).
Remove
and discard strain relief bushing
and adapter.
Remove wire nuts and disconnect power
cord lead wires.
Make conduit connection to chassis.
Connect permanent wiring leads to power-
head leads and re-install wire nuts.
Re -install c over .
Page 20
115VOLT
60 HERTZ
GROUNDED
ELECTRICAL
OUTLET
- - -1
WIRE NUTS •.
BLACK, WHITE AND
GREEN
POWER LEADS
()