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Learn how to Replace The primary Gear In A Garage Door Opener
It’s 6:00 AM and you’re leaving for work. You press the garage door opener wall button and hear a subtle hum from your electric motor however the door failed to maneuver. If your garage doors springs are intact chances are high you garage door openers main drive gear has failed. You may easily inspect your drive gears by unplugging your garage door opener and removing the metal cover. The principle drive gear is fabricated from a white plastic that typically is the weak link within the opener. Many things may cause this gear light switch hot touch to fail. Some causes of wear are:
o Garage door out of balance (Springs broke or in need of adjustment)
o Chain to tight a
o Old age
o Excessive use or high cycle
o Factory defect or lack of grease at time of manufacture
Replacing the large white gear is a low cost, quick and simple do it yourself repair as long as you’ve a few simple hand tools and follow the safety precautions. These gears may be purchased online in a wide range of levels of components.
Before you get started it is vital so that you can have a listing of the few simple tools needed to accomplish this project:
o Half inch wrench or adjustable wrench or pliers
o 3/8″ Socket or Nut Driver
o 1/4″ Socket or Nut Driver
o 5/16″ Socket or Nut Driver
o Flat Standard Screwdriver
o 5/32″ Punch or similar
To forestall possible SERIOUS INJURY or even DEATH from electrocution, ALWAYS Disconnect the facility cord out of your garage door from the outlet before proceeding with any inspection or repair.
Be sure that your garage door opener is unplugged. This step insures that no one unintentionally attempts to open or close the garage door if you are engaged on it or you don’t accidentally activate the door while servicing it.
Disconnect the door from the outer trolley by manually pulling the red disconnect rope and manually close the garage door.
The Garage door Have to be within the fully closed position during all repairs and inspection.
Assuring that your garage door is closed will reassure that your door is not going to fall or make any movement that will cause injury or startle you. We recommend that after the door is closed that you just clamp the door down using a vise grip or clamp above one of many rollers to prevent the door from being opened from the surface.
Slacken the chain or belts tension by losing the tension nut on the garage door opener trolley. Typically this is nut and will be adjusted with a ½” wrench.
Remove the sprocket or belt pulley retainer cap. Usually this has a clip on the back when you press in it will release.
I always recommend marking the position of the chain or belt to the sprocket prior to removing. This may easily be done with white out, tape or some other means. This step helps assure that your chain or belt gets reinstalled in the proper position and makes for quick and simple reference if needed later. Remove the chain or belt from the sprocket after which slide the inner trolley to the closed position until it engages the outer trolley. Place loose chain/belt on the tip of the rail closest to the sprocket. I typically duct tape the chain to prevent it from falling to the floor and getting all twisted and dirty.
It’s now time to remove both end covers and the principle housing. The end cover are each attached by three or four ¼” head screws that may be removed with a ¼” nut driver or socket. You should definitely unplug the wire to the circuit board.
Remove the retaining clip and the drive gear for the bounds. Also at this time remove the limit switch assembly by squeezing the sides just below the bracket by the drive gears. There isn’t a need to disconnect the wires as it’s OK to go away this limit assembly hang by the wires. Don’t make any adjustments to the limit assembly screws, this can insure that there’s minimal adjustment needed to the bounds after you complete your repair and run your garage door opener.
Now its time to remove the RPM sensor this may be easily done by unplugging the wire harness and take away the RPM sensor from the securing tabs.
Disconnect the red, blue and white wires from the motor. It is crucial that you simply light switch hot touch note where these wires go. The identical color wires go to the same terminals on the capacitor red/red and blue/blue.
Remove the four 5/16″ hex head screw’s that hold the motor assembly to the frame of the garage door opener. Be certain to place your hand under the motor before removing the last screw to stop the motor from falling. Slide the motor assembly off the drive shaft and place in a safe place. (Not on top of the ladder for obvious reasons).
Remove the three hex head screws holding the sprocket assembly to the primary chassis using a 5/16″ nut driver or socket. Now it’s time to decide if you want to replace the main gear only or your entire sprocket or all chain drive models 1984 to present.
Skip this step if you are replacing your complete gear and sprocket or pulley assembly. If you are going to replace the drive gear support the driveshaft on a block of wood and drive the lower roll pin/Tension pin out with a 5/32″ punch. See photo example below.
Remove and replace the worm gear. Typically it’s not essential to replace the worm gear unless it shows signs of wear. When you want to replace this gear remove the shaft collar with a 1/8″ hex wrench. Please be certain to notice the placement of each of those components as you disassemble so you’ll be able to re-install in proper order. Once you receive your gear kit, one can find there are parts not utilized in your model it’s because these kits are universal and work with many models of Sears, Craftsman, Wayne Dalton, Master Mechanic, Liftmaster, True Value and other brands of garage doors openers. Only replace the parts that are used on your garage door opener. Remove the three nuts that hold the motor to the frame and then remove the worm gear. Install the brand new worm gear ensuring the roll pin is properly seated in the brand new gear. Re-install other components in reverse order. After you complete this assembly I recommend you lube the worm gear so you do not forget.
Begin reassembly in reverse order. You’ll want to thoroughly lube the primary drive gear and that grease is on each tooth. Attach the gear and sprocket or pulley assembly to the principle chassis with the three 5/16″ head screws. Install the assembled motor frame to the chassis with the four 5/16″ head screws and reattach the red, blue and white wires; now install the limit assembly and the limit drive gear ensuring they mesh properly. Now you can install the RPM sensor and reconnect wires. Install the metal cover and end panels, you’ll want to plug in the circuit board and reconnect photo eye and push button wires.
Reconnect the facility cord to the opener and cycle the opener until the sprocket completes a complete clockwise cycle. The trolley must be within the fully down position before installing the chain. Now you’ll be able to remove the tape from the rail and reinstall the chain. The chain and sprocket reference mark ought to be near lining up. Tighten the chain so that the chain is ½” above the bottom of the rail at midpoint for “T” style rails and ¼” for square tube rails. Secure the chain tightening lock nut.
Note when adjusting and testing your garage door motor it will be significant
to make sure nobody is in the trail of the moving door.
It is important to know when testing your garage door opener it is feasible to over cycle the motor
and have the motor temporarily overheat and stop operating.
To stop this try and not operate the door opener greater than 10 cycles
without giving it 5-10 minutes to cool off
Now run the opener and test to see if the door opens to the proper position and closes to the proper position. If you have to make adjustments use the travel adjustments screws to make fine adjustments. I like to recommend only making slight adjustments ¼ turn or less at a time. For reference one full turn of the screw equals approx 2″ of travel on ½ and ¼ HP models and 3″ on ¾ HP models.
After getting your doors travel adjustment correct it is time to regulate the force. This is the pressure that it takes to assure your door opener will operate safely. Step one on this process is to check the down force. With the door open simply activate the garage door opener and when the door reaches the half way point grasp the door from the underside and attempt to stop it. If the door is hard to stop or doesn’t stop decrease the down force adjustment in small increments until it reverse upon reasonable force. If the door doesn’t close and the light begins to blink increase the down force adjustment in small increments until you may check the reversal at half way. Adjusting the force doesn’t guarantee that your operator will reverse on 1-1/2″ object at the floor. For more information on adjusting the reversal at the floor see your owner’s manual or call the manufacturer.
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