Chamberlain CG40DM User Manual

GARAGE DOOR OPENER

Model CG40DM 1/2 HP

For Residential Use Only

The Chamberlain Group, Inc.

845 Larch Avenue

Elmhurst, Illinois 60126-1196

www.chamberlain.com

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

■ Periodic checks of the opener are required to ensure safe operation.

■ The model number label is located on the front panel of your opener.

is connected and properly aligned.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Hang the opener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Install the door control . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Install the light and lens . . . . . . . . . . . . . . . . . . . . . . . . . 17

Attach the emergency release rope and handle. . . . . . . . 17

Electrical requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Install The Protector System

Fasten the door bracket. . . . . . . . . . . . . . . . . . . . . . . 23-24

Connect the door arm to the trolley . . . . . . . . . . . . . 25-26

. . . . . . . . . . . . . . . . . . 19-22

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

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.

When you see these Safety Symbols and Signal Words on the following pages, they will alert you to the possibility

Mechanical

Electrical

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.

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.

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.

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.

Sectional Door

Stepladder

One-Piece Door

Carpenter’s Level (optional)

Drill

Sockets and Wrench 1/2", 5/8", 7/16", 9/16" and 1/4"

Tape Measure

Drill Bits 3/16", 5/16" and 5/32"

Tools needed

During assembly, installation and adjustment of the opener, instructions will call for hand tools as illustrated below.

Pencil

Wire Cutters

Pliers

Hack Saw

Claw Hammer

Screwdriver

Adjustable End Wrench

— — — — — — — —

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 ﬁ nd 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 ﬁ nished 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 ﬂ oor 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.

• Look at the garage door where it meets the ﬂ oor. Any gap between the ﬂ oor 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, ﬁ berglass or glass panel door? If so, horizontal and vertical reinforce ment 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.

SECTIONAL DOOR INSTALLATION

Horizontal and vertical reinforcement is needed for lightweight garage doors (ﬁ berglass, steel, aluminum, door with glass panels, etc.). See page 23 for details.

Header Wall

Vertical Centerline of Garage Door

Gap between ﬂ oor and bottom of

Safety Reversing Sensor

door must not exceed 1/4" (6 mm).

Slack in chain tension is normal when garage door is closed.

Extension Spring

Torsion Spring

Wall-mounted Door Control

Safety Reversing Sensor

FINISHED CEILING

Support bracket & fastening hardware is required. See page 15.

Access Door

Header Wall

Garage Door

Motor Unit

Header Bracket

Garage Door Spring

Trolley Stop Bolt

Door Bracket

Curved Door Arm

CLOSED POSITION

Trolley

Emergency Straight Door Arm

Release

& Handle

Chain

Rope

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).

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 ﬂ oor MUST NOT exceed 1/4" (6 mm). Otherwise, the safety reversal system may NOT work properly.

• The ﬂ oor or the garage door MUST be repaired to eliminate the gap.

ONE-PIECE DOOR WITHOUT TRACK

Header Wall

Gap between ﬂ oor and bottom of

Safety Reversing Sensor

door must not exceed 1/4" (6 mm).

ONE-PIECE DOOR WITH TRACK

FINISHED CEILING

Support bracket & fastening hardware is required. See page 15.

Rail

Access Door

Safety Reversing Sensor

Slack in chain tension is normal when garage door is closed.

Wall-mounted Door Control

Trolley Stop Bolt

Header Bracket

Door Bracket

Header Wall

Motor Unit

CLOSED POSITION

Straight Door Arm

Garage Door

Rail

Chain

Curved Door Arm

Trolley

Emergency

Release Rope &

Handle

Safety Reversing Sensor

Access Door

Safety Reversing Sensor

Gap between ﬂ oor and bottom of door must not exceed 1/4" (6 mm).

Header Wall

CLOSED POSITION

Trolley Stop Bolt

Header Bracket

Door Bracket

Garage Door

Cable

Curved Door Arm

Straight Door Arm

Chain

Rail

Emergency Release Rope & Handle

Carton Inventory

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.

Lighted Door Control Button

with (2) screws 6ABx1-1/2"

2-Conductor Bell Wire White & White/Red

“U” Bracket

Rail Front (header) Section

Idler Pulley

Chain and Cable in Dispensing Carton

SECURITY✚ Single-Button Remote Control

Trolley

Motor Unit with a Light Lens

Rail Center/Back Sections

Door Bracket

Curved Door Arm Section

Hanging Brackets

Chain Spreader

Header Bracket

Straight Door Arm Section

Safety Reversing Sensor Bracket (2)

The Protector System (2) Safety Reversing Sensors (1 Sending Eye and 1 Receiving Eye) with 2-Conductor White & White/Black Bell Wire attached

Safety Labels and Literature

Hardware Inventory

Separate all hardware and group as shown below for the assembly and installation procedures.

ASSEMBLY HARDWARE

Lock Nut 1/4"-20 (2)

Bolt 1/4"-20x1-3/4" (2)

Carriage Bolt 1/4"-20x1/2" (2)

Lag Screw 5/16"-9x1-5/8" (2)

Lag Screw 5/16"-18x1-7/8" (2)

Lock Washer 3/8" (1)

Trolley Threaded Shaft (1)

Nut 3/8" (1)

Master Link (2)

INSTALLATION HARDWARE

Wing Nut 1/4"-20 (2)

INSTALLATION HARDWARE

Fastener (3)

Hex Bolt 5/16"-18x7/8" (4)

Screw 6ABx1-1/4" (2)

Nut 5/16"-18 (8)Ring

Lock Washer 5/16" (7)

Insulated Staples (30)

Screw 6-32x1" (2)

Idler Bolt (1)

Handle

Self-Threading Screw 1/4"-14x5/8" (2)

Clevis Pin 5/16"x1-1/2" (1)

Drywall Anchors (2)

Clevis Pin 5/16"x1" (1)

Rope

Clevis Pin 5/16"x1-1/4" (1)

ASSEMBLY STEP 1

Assemble the Rail & Install the Trolley

To avoid installation difﬁ culties, do not run the garage door opener until instructed to do so.

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 ﬂ at 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.

To prevent INJURY from pinching, keep hands and ﬁ ngers away from the joints while assembling 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.

Trolley

Tapered End

Screwdriver

Idler Pulley Hole

Window Cut-Out

Front Rail (TO DOOR)

KEEP LARGER HOLE ON TOP

FRONT RAIL (TOP)

Tabs

Tapered End

Back Rails (TO MOTOR UNIT)

Tapered End

Outer Trolley

Tapered End

Inner Trolley

Wear Pads

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, ﬂ at 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.

HARDWARE SHOWN ACTUAL SIZE

Lock Nut 1/4"-20

Bolt 1/4"-20x1-3/4"

To avoid SERIOUS damage to garage door opener, use ONLY those bolts/fasteners mounted in the top of the opener.

Hex Screws

8-32x7/16"

Bolts

“U” Bracket

Bolt

Cover Protection Bolt Hole

SLIDE RAIL TO STOPS

Lock Nut

ON TOP AND SIDES OF BRACKET

Chain Spreader

Motor Unit Sprocket

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

Idler Bolt

Lock

Washer

3/8"

Chain and Cable

Screwdriver

Nut 3/8"

Cable Link

Bolt

Pulley

Washer

Trolley

Grease Inside Pulley

Idler Pulley

Bolt 1/4"-20x1-3/4"

Rail

Nut

Trolley Stop Hole

Idler Pulley

Bolt

Lock Nut

Lock Washer 3/8"

Lock Nut 1/4"-20

Nut 3/8"

Idler Bolt

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.

Figure 2

“U” Bracket

Bolt

Chain Spreader

Motor Unit Sprocket

To avoid possible SERIOUS INJURY to ﬁ ngers from moving garage door opener:

• ALWAYS keep hand clear of sprocket while operating opener.

• Securely attach chain spreader BEFORE operating.

Dispensing Carton

Leave Chain and Cable Inside Dispensing Carton to Prevent Kinking.

Keep Chain and Cable Taut When Dispensing

Figure 1

Master Link Cap

Pin Notch

Master Link Bar

Master Link

Clip-On Spring

Cable

Link

Idler Pulley

Cable

Master Link

Clip-On Spring

Master Link Cap

Slotted

Hole

Master

Link Bar

Trolley

Threaded

Shaft

Round Hole

Figure 4

Round Hole

Trolley Threaded Shaft

Figure 3

Lock 5/16" Washer

Inner Nut 5/16"

Trolley Threaded Shaft

ASSEMBLY STEP 5

WARNING

WARNING WARNING

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 ﬁ nished assembling your garage door opener. Please read the following warnings before proceeding to the installation section.

Figure 1

Figure 2

To Tighten Outer Nut

Chain

Base of Rail

Outer

Lock

Nut

Washer

To Tighten Inner Nut

1/4" (6 mm)

Mid length of Rail

Trolley Threaded Shaft

Inner Nut

INSTALLATION

IMPORTANT INSTALLATION INSTRUCTIONS

To reduce the risk of SEVERE INJURY or DEATH:

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 ﬂ oor.

6. Mount the emergency release within reach, but at least 6 feet (1.83 m) above the ﬂ oor and avoiding contact with vehicles to avoid accidental release.

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 ﬂ at) on the ﬂ oor.

INSTALLATION STEP 1

Determine the Header Bracket Location

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.

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 inter secting 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.

Header

Wall

Header Wall

Highest Point of Travel

Door

Sectional door with curved track

Header Wall

Door

Jamb

Hardware

Unﬁ nished

Ceiling

Vertical Centerline

of Garage Door

Level (optional)

2" (5 cm)

Track

8" (20 cm)

Highest Point of Travel

2x4

Header Wall

Door

One-piece door with horizontal track

Header Wall

8" (20 cm)

Door

OPTIONAL CEILING MOUNT FOR HEADER BRACKET

Structural

Supports

2" (5 cm)

Track

Highest Point of Travel

Pivot

One-piece door without track: jamb hardware

One-piece door without track: pivot hardware

+ 28 hidden pages

Chamberlain CG40DM User Manual

TABLE OF CONTENTS

INTRODUCTION

Safety Symbol and Signal Word Review

Preparing your garage door

Tools needed

Planning

Carton Inventory

Hardware Inventory

Assemble the Rail & Install the Trolley

Fasten the Rail to the Motor Unit

Install the Idler Pulley

Install the Chain/Cable

Tighten the Chain

INSTALLATION

Determine the Header Bracket Location