Chamberlain CG40D 1-2 HP User Manual
The Chamberlain Group, Inc.
845 Larch Avenue
Elmhurst, Illinois 60126-1196
www.chamberlain.com
GARAGE DOOR OPENER
Model CG40D 1/2 HP
For Residential Use Only
Owner’s Manual
■ Please read this manual and the enclosed safety materials carefully!
■ Fasten the manual near the garage door after installation.
■ The door WILL NOT CLOSE unless The Protector System
®
is connected and properly
aligned.
■ Periodic checks of the opener are required to ensure safe operation.
■ The model number label is located on the front panel of your opener.
2
TABLE OF CONTENTS
When you see these Safety Symbols and Signal Words on
the following pages, they will alert you to the possibility of
serious injury or death if you do not comply with the
warnings that accompany them. The hazard may come
from something mechanical or from electric shock. Read
the warnings carefully.
When you see this Signal Word on the following pages, it
will alert you to the possibility of damage to your garage
door and/or the garage door opener if you do not comply
with the cautionary statements that accompany it. Read
them carefully.
INTRODUCTION
Safety Symbol and Signal Word Review
This garage door opener has been designed and tested to offer safe service provided it is installed, operated,
maintained and tested in strict accordance with the instructions and warnings contained in this manual.
Mechanical
Electrical
Introduction 2-7
Safety symbol and signal word review ...............................2
Preparing your garage door................................................3
Tools needed.......................................................................3
Planning ..........................................................................4-5
Carton inventory..................................................................6
Hardware inventory.............................................................7
Assembly 8-11
Assemble the rail and install the trolley ..............................8
Fasten the rail to the motor unit and
install the idler pulley ..........................................................9
Install the chain/cable .......................................................10
Tighten the chain...............................................................11
Installation 11-26
Installation safety instructions ...........................................11
Determine the header bracket location.............................12
Install the header bracket .................................................13
Attach the rail to the header bracket.................................14
Position the opener...........................................................15
Hang the opener ...............................................................16
Install the door control ......................................................17
Install the light and lens ....................................................18
Attach the emergency release rope and handle...............18
Electrical requirements .....................................................19
Install The Protector System®......................................20-22
Fasten the door bracket...............................................23-24
Connect the door arm to the trolley.............................25-26
Adjustment 27-29
Adjust the travel limits.......................................................27
Adjust the force.................................................................28
Test the safety reversal system ........................................29
Test The Protector System®..............................................29
Operation 30-34
Operation safety instructions ............................................30
Using your garage door opener........................................30
Using the wall-mounted Door Control...............................31
To open the door manually ...............................................31
Care of your garage door opener .....................................32
Having a problem?............................................................33
Diagnostic chart ................................................................34
Programming 35-36
To add or reprogram a hand-held remote control.............35
To erase all codes.............................................................35
3-Button Remotes .............................................................35
To add, reprogram or change
a Keyless Entry PIN..........................................................36
Repair Parts 37-38
Rail assembly parts...........................................................37
Installation parts................................................................37
Motor unit assembly parts.................................................38
Accessories 39
Repair Parts and Service 40
Warranty 40
3
To prevent damage to garage door and opener:
• ALWAYS disable locks BEFORE installing and operating the
opener.
• ONLY operate garage door opener at 120V, 60 Hz to avoid
malfunction and damage.
To prevent possible SERIOUS INJURY or DEATH:
• ALWAYS call a trained door systems technician if garage
door binds, sticks, or is out of balance. An unbalanced
garage door may not reverse when required.
• NEVER try to loosen, move or adjust garage door, door
springs, cables, pulleys, brackets or their hardware, ALL of
which are under EXTREME tension.
• Disable ALL locks and remove ALL ropes connected to
garage door BEFORE installing and operating garage door
opener to avoid entanglement.
Preparing your garage door
Before you begin:
• Disable locks.
• Remove any ropes connected to garage door.
• Complete the following test to make sure your garage
door is balanced and is not sticking or binding:
1. Lift the door about halfway as shown. Release the
door. If balanced, it should stay in place, supported
entirely by its springs.
2. Raise and lower the door to see if there is any
binding or sticking.
If your door binds, sticks, or is out of balance, call a
trained door systems technician.
Tools needed
During assembly, installation and adjustment of the
opener, instructions will call for hand tools as illustrated
below.
2
1
Sectional Door
One-Piece Door
Carpenter’s
Level (optional)
Drill
Tape Measure
Drill Bits
3/16", 5/16"
and 5/32"
Pencil
Hack Saw
Claw Hammer
Wire Cutters
Screwdriver
Stepladder
Sockets and Wrench
1/2", 5/8", 7/16", 9/16"
and 1/4"
Pliers
Adjustable End Wrench
4
Safety Reversing Sensor
Horizontal and vertical reinforcement
is needed for lightweight garage doors
(fiberglass, steel, aluminum,
door with glass panels, etc.).
See page 23 for details.
— — — — — — — —
Header Wall
Safety
Reversing
Sensor
Gap between floor and bottom of door
must not exceed 1/4" (6 mm).
Extension Spring
Torsion Spring
Access
Door
OR
Slack in chain tension
is normal when
garage door is closed.
Wall-mounted
Door
Control
Motor Unit
FINISHED CEILING
Support bracket &
fastening hardware
is required.
See page 16.
Vertical
Centerline
of Garage Door
SECTIONAL DOOR INSTALLATION
Planning
Identify the type and height of your garage door. Survey
your garage area to see if any of the conditions below
apply to your installation. Additional materials may be
required. You may find it helpful to refer back to this page
and the accompanying illustrations as you proceed with
the installation of your opener.
Depending on your requirements, there are several
installation steps which may call for materials or hardware
not included in the carton.
• Installation Step 1 – Look at the wall or ceiling above
the garage door. The header bracket must be securely
fastened to structural supports.
• Installation Step 5 – Do you have a finished ceiling in
your garage? If so, a support bracket and additional
fastening hardware may be required.
• Installation Step 10 – Depending upon garage
construction, extension brackets or wood blocks may be
needed to install sensors.
• Installation Step 10 – Alternate floor mounting of the
safety reversing sensor will require hardware not
provided.
• Do you have an access door in addition to the garage
door? If not, Model 7702CB Emergency Key Release is
required. See Accessories page.
Trolley
Header
Wall
Garage
Door
Header
Bracket
Straight
Door
Arm
Emergency
Release
Rope & Handle
Door
Bracket
Curved
Door
Arm
Garage
Door
Spring
Chain
Trolley
Stop Bolt
CLOSED POSITION
• Look at the garage door where it meets the floor. Any
gap between the floor and the bottom of the door must
not exceed 1/4" (6 mm). Otherwise, the safety reversal
system may not work properly. See Adjustment Step 3.
Floor or door should be repaired.
SECTIONAL DOOR INSTALLATIONS
• Do you have a steel, aluminum, fiberglass or glass
panel door? If so, horizontal and vertical reinforcement
is required (Installation Step 11).
• The opener should be installed above the center of the
door. If there is a torsion spring or center bearing plate
in the way of the header bracket, it may be installed
within 4 feet (1.22 m) to the left or right of the door
center. See Installation Steps 1 and 11.
• If your door is more than 7 feet (2.13 m) high, see rail
extension kits listed on Accessories page.
5
Planning (Continued)
ONE-PIECE DOOR INSTALLATIONS
• Generally, a one-piece door does not require
reinforcement. If your door is lightweight, refer to the
information relating to sectional doors in Installation
Step 11.
• Depending on your door’s construction, you may need
additional mounting hardware for the door bracket
(Step 11).
ONE-PIECE DOOR WITHOUT TRACK
Without a properly working safety reversal system, persons
(particularly small children) could be SERIOUSLY INJURED or
KILLED by a closing garage door.
• The gap between the bottom of the garage door and the floor
MUST NOT exceed 1/4" (6 mm). Otherwise, the safety
reversal system may not work properly.
• The floor or the garage door MUST be repaired to eliminate
the gap.
ONE-PIECE DOOR WITH TRACK
FINISHED CEILING
Support bracket
& fastening
hardware is required.
See page 16.
Header Wall
Rail
Slack in chain tension
is normal when garage
door is closed.
Wall-mounted
Door Control
Access
Door
Motor Unit
CLOSED POSITION
Trolley Stop Bolt
Cable
Trolley
Safety Reversing Sensor
Safety
Reversing Sensor
Safety Reversing
Gap between floor
and bottom of door must not exceed 1/4" (6 mm).
Gap between floor
and bottom of door
must not exceed 1/4" (6 mm).
Sensor
Access
Door
Safety
Reversing
Sensor
Header
Wall
Door Bracket
Header
Wall
CLOSED POSITION
Trolley Stop Bolt
Header
Bracket
Door
Bracket
Garage
Door
Header
Bracket
Curved
Door Arm
Straight
Door
Arm
Garage Door
Cable
Straight
Door
Arm
Rail
Curved
Door
Arm
Chain
Rail
Emergency
Release
Rope &
Handle
Emergency
Release
Rope & Handle
6
Your garage door opener is packaged in one carton which
contains the motor unit and all parts illustrated below.
Accessories will depend on the model purchased. If
anything is missing, carefully check the packing material.
PARTS MAY BE STUCK IN THE FOAM. Hardware for
assembly and installation is shown on the next page. Save
the carton and packing material until installation and
adjustment is complete.
Carton Inventory
Lighted Door Control Button
with (2) screws 6ABx1-1/2"
2-Conductor Bell Wire
White & White/Red
Motor Unit with a Light Lens
Chain Spreader
Trolley
"U" Bracket
Rail
Front (header)
Section
Safety Sensor
Bracket (2)
Idler Pulley
Chain and Cable in
Dispensing Carton
Rail
Center/Back
Sections
Curved Door
Arm Section
The Protector System
(2) Safety Reversing Sensors
(1 Sending Eye and 1 Receiving Eye)
with 2-Conductor White
& White/Black Bell Wire attached
®
Header Bracket
Door Bracket
Hanging Brackets
Safety Labels
Straight Door
Arm Section
and
Literature
7
Hardware Inventory
Separate all hardware and group as shown below for the assembly and installation procedures.
ASSEMBLY HARDWARE
INSTALLATION HARDWARE
Lock Nut
1/4"-20 (2)
Bolt 1/4"-20x1-3/4 (2)
Carriage Bolt
1/4"-20x1/2" (2)
Trolley Threaded Shaft (1)
Wing Nut
1/4"-20 (2)
Lock Washer
3/8" (1)
Ring
Fastener (3)
Nut 5/16"-18 (8)
Nut
3/8" (1)
Master
Link (2)
Idler Bolt (1)
Handle
5/16"-9x1-5/8" (2)
Lag Screw
5/16"-18x1-7/8" (2)
Self-Threading Screw
1/4"-14x5/8" (2)
Clevis Pin
5/16"x1-1/2" (1)
Hex Bolt
5/16"-18x7/8" (4)
Screw
6ABx1-1/4" (2)
Drywall Anchors (2)
Clevis Pin
5/16"x1" (1)
Lock Washer 5/16" (7) Lag Screw
Clevis Pin
5/16"x1-1/4" (1)
Insulated
Staples (30)
Screw 6-32x1" (2)
Spacer (2)
Rope
8
ASSEMBLY STEP 1
Assemble the Rail & Install the Trolley
To avoid installation difficulties, do not run the garage
door opener until instructed to do so.
Front Rail
(TO DOOR)
Window
Cut-Out
Screwdriver
Idler
Pulley
Hole
Ta bs
Back Rails
(TO MOTOR UNIT)
Trolley
Tapered
End
Tapered
End
Inner Trolley
Wear Pads
Outer Trolley
Tapered
End
Tapered
End
To prevent INJURY from pinching, keep hands and fingers
away from the joints while assembling the rail.
The front rail has a cut out “window” at the door end (see
illustration). The hole above this window is larger on
the top of the rail than on the bottom. A smaller hole
3-1/2" (8.9 cm) away is close to the rail edge. Rotate the
back rail so it has a similar hole close to the opposite
edge, about 4-3/4" (12 cm) from the far end.
1. Remove the straight door arm and hanging bracket
packaged inside the front rail and set aside for
Installation Step 5 and 12. NOTE: To prevent INJURY
while unpacking the rail carefully remove the straight
door arm stored within the rail section.
2. Align the rail sections on a flat surface as shown and
slide the tapered ends into the larger ones. Tabs along
the side will lock into place.
3. Place the motor unit on packing material to protect the
cover, and rest the back end of the rail on top. For
convenience, put a support under the front end of the
rail.
4. As a temporary trolley stop, insert a screwdriver into the
hole 10" (25 cm) away from the front of the rail, as
shown.
5. Check to be sure there are 4 plastic wear pads inside
the inner trolley. If they became loose during shipping,
check all packing material. Snap them back into position
as shown.
6. Slide the trolley assembly along the rail from the back
end to the screwdriver.
KEEP LARGER
HOLE ON TOP
FRONT RAIL
(TOP)
9
To avoid SERIOUS damage to garage door opener, use ONLY
those bolts/fasteners mounted in the top of the opener.
ASSEMBLY STEP 2
Fasten the Rail to the Motor Unit
• Insert a 1/4"-20x1-3/4 bolt into the cover protection bolt
hole on the back end of the rail as shown. Tighten
securely with a 1/4"-20 lock nut. Do NOT overtighten.
• Remove the two bolts from the top of the motor unit.
• Place the “U” bracket, flat side down onto the motor unit
and align the bracket hole with the bolt holes. Fasten
with the previously removed bolts.
• Align the rail assembly with the top of the motor unit.
Slide the rail end onto the “U” bracket, all the way to the
stops that protrude on the top and sides of the bracket.
• Attach spreader to the motor unit with two screws.
ASSEMBLY STEP 3
Install the Idler Pulley
• Lay the chain/cable beside the rail, as shown. Grasp the
end of the cable and pass approximately 12" (30 cm) of
cable through the window. Allow it to hang until
Assembly Step 5.
• Remove the tape from the idler pulley. The inside center
should be pre-greased. If dry, regrease to ensure proper
operation.
• Place the idler pulley into the window as shown.
• Insert the idler bolt from the top through the rail and
pulley. Tighten with a 3/8" lock washer and nut
underneath the rail until the lock washer is compressed.
• Rotate the pulley to be sure it spins freely.
• Insert a 1/4"-20x1-3/4 bolt into the trolley stop hole in
the front of the rail as shown. Tighten securely with a
1/4"-20 lock nut.
HARDWARE SHOWN ACTUAL SIZE
HARDWARE SHOWN ACTUAL SIZE
Hex Screws
8-32x7/16"
Chain
Spreader
Motor Unit
Sprocket
Cover
Protection
Bolt Hole
Bolts
"U" Bracket
Bolt
Lock Nut
Bolt 1/4"-20x1-3/4"
1/4"-20
Chain and
Cable
Idler
Bolt
Lock
Washer
3/8"
Lock Nut
Screwdriver
Nut 3/8"
SLIDE RAIL TO STOPS
ON TOP AND SIDES
OF BRACKET
Pulley
Washer
Trolley
Cable Link
Bolt
Rail
Nut
Trolley
Stop Hole
Grease
Inside Pulley
Idler
Pulley
Bolt
Idler Bolt
Bolt 1/4"-20x1-3/4"
Lock Nut 1/4"-20
Nut 3/8"
Idler
Pulley
Lock Washer 3/8"
Lock
Nut
10
To avoid possible SERIOUS INJURY to fingers from moving
garage door opener:
• ALWAYS keep hand clear of sprocket while operating opener.
• Securely attach chain spreader BEFORE operating.
t
Figure 1
Figure 2
Figure 3
Figure 4
Round
Hole
Trolley
Threaded
Shaft
ASSEMBLY STEP 4
Install the Chain/Cable
1. Pull the cable around the idler pulley and toward the
trolley.
2. Connect the cable to the retaining slot on the trolley, as
shown (Figure 1):
• From below, push pins of master link bar up through
cable link and trolley slot.
• Push master link cap over pins and past pin notches.
• Slide clip-on spring over cap and onto pin notches
until both pins are securely locked in place.
3. With the trolley against the screwdriver, dispense the
remainder of the cable/chain along the rail toward the
motor unit into the slot on the chain spreader, around
the sprocket onto the chain spreader and continuing to
the trolley assembly. The sprocket teeth must engage
the chain (Figure 2).
4. Check to make sure the chain is not twisted, then
connect it to the threaded shaft with the remaining
master link.
5. Thread the inner nut and lock washer onto the trolley
threaded shaft (Figure 3).
6. Insert the trolley threaded shaft through the hole in the
trolley. Be sure the chain is not twisted (Figure 4).
7. Loosely thread the outer nut onto the trolley threaded
shaft.
8. Remove the screwdriver.
Chain
"U" Bracket
Bolt
Spreader
Motor Uni
Sprocket
Dispensing Carton
Leave Chain and Cable
Inside Dispensing
Carton to Prevent Kinking.
Keep Chain and Cable
Taut When Dispensing
Master Link
Clip-On Spring
Master Link
Idler
Pulley
Clip-On Spring
Cable
Link
Cable
Master
Link Cap
Slotted
Hole
Master
Link Bar
Trolley
Threaded
Shaft
Round
Hole
Master
Link Cap
Pin
Notch
Master
Link Bar
Trolley
Threaded
Inner Nut
5/16"
Lock
Washer
5/16"
Shaft
11
INSTALLATION
ASSEMBLY STEP 5
Tighten the Chain
• Spin the inner nut and lock washer down the trolley
threaded shaft, away from the trolley.
• To tighten the chain, turn outer nut in the direction
shown (Figure 1).
• When the chain is approximately 1/4" (6 mm) above the
base of the rail at its midpoint, re-tighten the inner nut to
secure the adjustment.
Sprocket noise can result if chain is too loose.
When installation is complete, you may notice some chain
droop with the door closed. This is normal. If the chain
returns to the position shown in Figure 2 when the door is
open, do not re-adjust the chain.
NOTE: During future maintenance, ALWAYS pull the
emergency release handle to disconnect trolley before
adjusting chain. You may notice loosening of chain after
Adjustment Step 3 (Test the Safety Reversal System).
Check for proper tension and readjust chain if necessary.
Then repeat Adjustment Step 3.
You have now finished assembling your garage door
opener. Please read the following warnings before
proceeding to the installation section.
Outer
Nut
Lock
Washer
Trolley
Threaded
Shaft
Inner Nut
To Tighten
Inner Nut
To Tighten Outer Nut
Base of Rail
Mid length of Rail
Chain
1/4" (6 mm)
Figure 1
Figure 2
IMPORTANT INSTALLATION INSTRUCTIONS
To reduce the risk of SEVERE INJURY or DEATH:
WARNING
WARNING
WARNINGWARNING
1. READ AND FOLLOW ALL INSTALLATION WARNINGS AND
INSTRUCTIONS.
2. Install garage door opener ONLY on properly balanced and
lubricated garage door. An improperly balanced door may not
reverse when required and could result in SEVERE INJURY or
DEATH.
3. ALL repairs to cables, spring assemblies and other hardware
MUST be made by a trained door systems technician BEFORE
installing opener.
4. Disable ALL locks and remove ALL ropes connected to
garage door BEFORE installing opener to avoid entanglement.
5. Install garage door opener 7 feet (2.13 m) or more above
floor.
6. Mount emergency release handle 6 feet (1.83 m) above floor.
7. NEVER connect garage door opener to power source until
instructed to do so.
8. NEVER wear watches, rings or loose clothing while
installing or servicing opener. They could be caught in
garage door or opener mechanisms.
9. Install wall-mounted garage door control:
• within sight of the garage door.
• out of reach of children at minimum height of 5 feet
(1.5 m).
• away from ALL moving parts of the door.
10. Place entrapment warning label on wall next to garage door
control.
11. Place manual release/safety reverse test label in plain view
on inside of garage door.
12. Upon completion of installation, test safety reversal system.
Door MUST reverse on contact with a 1-1/2"
(3.8 cm) high object (or a 2x4 laid flat) on the floor.
12
INSTALLATION STEP 1
Determine the Header Bracket
Location
Installation procedures vary according to garage door
types. Follow the instructions which apply to your door.
1. Close the door and mark the inside vertical centerline of
the garage door.
2. Extend the line onto the header wall above the door.
You can fasten the header bracket within 4 feet
(1.22 m) of the left or right of the door center only if
a torsion spring or center bearing plate is in the
way; or you can attach it to the ceiling (see page 13)
when clearance is minimal. (It may be mounted on
the wall upside down if necessary, to gain
approximately 1/2" (1 cm).
If you need to install the header bracket on a 2x4
(on wall or ceiling), use lag screws (not provided)
to securely fasten the 2x4 to structural supports as
shown here and on page 13.
3. Open your door to the highest point of travel as shown.
Draw an intersecting horizontal line on the header wall
above the high point:
• 2" (5 cm) above the high point for sectional door and
one-piece door with track.
• 8" (20 cm) above the high point for one-piece door
without track.
This height will provide travel clearance for the top edge
of the door.
NOTE: If the total number of inches exceeds the height
available in your garage, use the maximum height
possible, or refer to page 13 for ceiling installation.
To prevent possible SERIOUS INJURY or DEATH:
• Header bracket MUST be RIGIDLY fastened to structural
support on header wall or ceiling, otherwise garage door
might not reverse when required. DO NOT install header
bracket over drywall.
• Concrete anchors MUST be used if mounting header bracket
or 2x4 into masonry.
• NEVER try to loosen, move or adjust garage door, springs,
cables, pulleys, brackets, or their hardware, ALL of which
are under EXTREME tension.
• ALWAYS call a trained door systems technician if garage
door binds, sticks, or is out of balance. An unbalanced
garage door might not reverse when required.
Header Wall
Sectional door with curved track
Highest Point
of Travel
Door
2" (5 cm)
One-piece door with horizontal track
Door
Track
Header Wall
Highest Point
of Travel
2" (5 cm)
Track
Header Wall
Vertical Centerline
of Garage Door
Level
(optional)
2x4
2x4
Structural
Supports
OPTIONAL
CEILING
MOUNT
FOR
HEADER
BRACKET
Unfinished
Ceiling
Door
Jamb
Hardware
One-piece door without track:
jamb hardware
8" (20 cm)
Highest
Point
of Travel
Door
Pivot
8" (20 cm)
One-piece door without track:
pivot hardware
Highest
Point
of Travel
Header Wall
Header Wall
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