The Chamberlain Group, Inc. 845 Larch Avenue Elmhurst, Illinois 60126-1196 www.chamberlain.com GARAGE DOOR OPENER Model CG40DM 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.
TABLE OF CONTENTS Introduction 2-7 Adjustment 27-29 Safety symbol and signal word review . . . . . . . . . . . . . . . 2 Adjust the travel limits . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Preparing your garage door . . . . . . . . . . . . . . . . . . . . . . . 3 Adjust the force. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Tools needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Test the safety reversal system. . . . . . . . . . . . . . .
Preparing your garage door Before you begin: • Disable locks. 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.
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. • 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).
Planning (Continued) ONE-PIECE DOOR INSTALLATIONS 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. • Generally, a one-piece door does not require reinforcement.
Carton Inventory 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. 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.
Hardware Inventory Separate all hardware and group as shown below for the assembly and installation procedures.
ASSEMBLY STEP 1 Assemble the Rail & Install the Trolley To prevent INJURY from pinching, keep hands and fingers away from the joints while assembling the rail. To avoid installation difficulties, do not run the garage door opener until instructed to do so. 4. As a temporary trolley stop, insert a screwdriver into the hole 10" (25 cm) away from the front of the rail, as shown. The front rail has a cut out “window” at the door end (see illustration).
ASSEMBLY STEP 2 Fasten the Rail to the Motor Unit To avoid SERIOUS damage to garage door opener, use ONLY those bolts/fasteners mounted in the top of the opener. • 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. Hex Screws 8-32x7/16" • Remove the two bolts from the top of the motor unit.
ASSEMBLY STEP 4 Install the Chain/Cable 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. 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.
Figure 1 ASSEMBLY STEP 5 Tighten the Chain To Tighten Outer Nut • Spin the inner nut and lock washer down the trolley threaded shaft, away from the trolley. Outer Nut Lock Washer Trolley Threaded Shaft Inner Nut • To tighten the chain, turn outer nut in the direction shown (Figure 1). To Tighten Inner Nut Figure 2 • 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.
Unfinished Ceiling INSTALLATION STEP 1 OPTIONAL CEILING MOUNT FOR HEADER BRACKET Determine the Header Bracket Location Header Wall 2x4 Vertical Centerline of Garage Door 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.
Wall Mount INSTALLATION STEP 2 Install the Header Bracket You can attach the header bracket either to the wall above the garage door, or to the ceiling. Follow the instructions which will work best for your particular requirements. Do not install the header bracket over drywall. If installing into masonry, use concrete anchors (not provided).
Header Wall Header Bracket Idler Pulley INSTALLATION STEP 3 Attach the Rail to the Header Bracket • Position the opener on the garage floor below the header bracket. Use packing material as a protective base. NOTE: If the door spring is in the way you’ll need help. Have someone hold the opener securely on a temporary support to allow the rail to clear the spring. Ring Fastener Header Bracket Clevis Pin • Position the rail bracket against the header bracket.
INSTALLATION STEP 5 Hang the Opener To avoid possible SERIOUS INJURY from a falling garage door opener, fasten it SECURELY to structural supports of the garage. Concrete anchors MUST be used if installing any brackets into masonry. Three representative installations are shown. Yours may be different. Hanging brackets should be angled (Figure 1) to provide rigid support. On finished ceilings (Figure 2 and Figure 3), attach a sturdy metal bracket to structural supports before installing the opener.
INSTALLATION STEP 6 Install the Door Control To prevent possible SERIOUS INJURY or DEATH from electrocution: • Be sure power is NOT connected BEFORE installing door control. • Connect ONLY to 24 VOLT low voltage wires. To prevent possible SERIOUS INJURY or DEATH from a closing garage door: • Install door control within sight of garage door, out of reach of children at a minimum height of 5 feet (1.5 m), and away from ALL moving parts of door.
INSTALLATION STEP 7 Install the Light and Lens To prevent possible OVERHEATING of the endpanel or light socket: • DO NOT use short neck or specialty light bulbs. • DO NOT use halogen bulbs. Use ONLY incandescent. To prevent damage to the opener: • DO NOT use bulbs larger than 75W. • ONLY use A19 size bulbs. INSTALL THE LIGHT • Install an A19 standard neck, 75 watt maximum light bulb in the socket. The light will turn ON and remain lit for approximately 4-1/2 minutes when power is connected.
INSTALLATION STEP 9 Electrical Requirements To prevent possible SERIOUS INJURY or DEATH from electrocution or fire: • Be sure power is NOT connected to the opener, and disconnect power to circuit BEFORE removing cover to establish permanent wiring connection. • Garage door installation and wiring MUST be in compliance with ALL local electrical and building codes. • NEVER use an extension cord, 2-wire adapter, or change plug in any way to make it fit outlet. Be sure the opener is grounded.
INSTALLATION STEP 10 Install The Protector System® Be sure power is NOT connected to the garage door opener BEFORE installing the safety reversing sensor. To prevent SERIOUS INJURY or DEATH from a closing garage door: • Correctly connect and align the safety reversing sensor. This required safety device MUST NOT be disabled. • Install the safety reversing sensor so beam is NO HIGHER than 6" (15 cm) above garage floor.
Figure 1 INSTALLING THE BRACKETS Be sure power to the opener is disconnected. Install and align the brackets so the sensors will face each other across the garage door, with the beam no higher than 6" (15 cm) above the floor. They may be installed in one of three ways, as follows. DOOR TRACK MOUNT (RIGHT SIDE) Door Track Lip Indicator Light Garage door track installation (preferred): • Slip the curved arms over the rounded edge of each door track, with the curved arms facing the door.
Figure 5 MOUNTING AND WIRING THE SAFETY REVERSING SENSORS Wing Nut 1/4"-20 Mounting: • Slide a 1/4"-20x1/2" carriage bolt head into the slot on each sensor. Use wing nuts to fasten sensors to brackets, with lenses pointing toward each other across the door. Be sure the lens is not obstructed by a bracket extension (Figure 5). Carriage Bolt 1/4"-20x1/2" Lens • Finger tighten the wing nuts.
Connect to garage door opener • Strip 1/4" (6 mm) of insulation from each set of wires. Separate white and white/black wires sufficiently to connect to the opener terminal screws: white to 2 and white/black to 3 (Figure 10). Figure 10 Connect Wire to Screw Terminals Bell Wire — Finished Ceiling — Bell Wire 1. Strip wire 7/16" (11 mm) 7/16" (11 mm) 2. Twist like colored wires together 3. Connect wire to the opener terminal screws: white to 2 and white/black to 3.
INSTALLATION STEP 11 Fasten the Door Bracket Fiberglass, aluminum or lightweight steel garage doors WILL REQUIRE reinforcement BEFORE installation of door bracket. Contact your door manufacturer for reinforcement kit. Follow instructions which apply to your door type as illustrated below or on the following page. A horizontal reinforcement brace should be long enough to be secured to two or three vertical supports. A vertical reinforcement brace should cover the height of the top panel.
ONE-PIECE DOORS Please read and comply with the warnings and reinforcement instructions on the previous page. They apply to one-piece doors also. • Center the door bracket on the top of the door, in line with the header bracket as shown. Mark either the left and right, or the top and bottom holes. HARDWARE SHOWN ACTUAL SIZE • Metal Doors: Drill 3/16" pilot holes and fasten the bracket with the 1/4"-14x5/8" self-threading screws provided.
Pulley INSTALLATION STEP 12 8" (20 cm) min. Connect Door Arm to Trolley Follow instructions which apply to your door type as illustrated below and on the following page. Trolley Stop Bolt SECTIONAL DOORS ONLY Ring Fastener Make sure garage door is fully closed. Pull the emergency release handle to disconnect the outer trolley from the inner trolley. Slide the outer trolley back (away from the pulley) about 8" (20 cm) as shown in Figures 1, 2 and 3.
Figure 5 ALL ONE-PIECE DOORS CORRECT INCORRECT 1. Assemble the door arm, Figure 5: IMPORTANT: The groove on the straight door arm MUST face away from the curved door arm. Straight Door Arm • Fasten the straight and curved door arm sections together to the longest possible length (with a 2 or 3 hole overlap). (Groove facing out) Straight Door Arm Curved Door Arm Curved Door Arm • With the door closed, connect the straight door arm section to the door bracket with the 5/16"x1-1/4" clevis pin.
ADJUSTMENT STEP 1 Adjust the UP and DOWN Travel Limits Without a properly installed safety reversal system, persons (particularly small children) could be SERIOUSLY INJURED or KILLED by a closing garage door. • Incorrect adjustment of garage door travel limits will interfere with proper operation of safety reversal system. • If one control (force or travel limits) is adjusted, the other control may also need adjustment. • After ANY adjustments are made, the safety reversal system MUST be tested.
ADJUSTMENT STEP 2 Adjust the Force Without a properly installed safety reversal system, persons (particularly small children) could be SERIOUSLY INJURED or KILLED by a closing garage door. • Too much force on garage door will interfere with proper operation of safety reversal system. • NEVER increase force beyond minimum amount required to close garage door. • NEVER use force adjustments to compensate for a binding or sticking garage door.
ADJUSTMENT STEP 3 Test the Safety Reversal System Without a properly installed safety reversal system, persons (particularly small children) could be SERIOUSLY INJURED or KILLED by a closing garage door. • Safety reversal system MUST be tested every month. • If one control (force or travel limits) is adjusted, the other control may also need adjustment. • After ANY adjustments are made, the safety reversal system MUST be tested. Door MUST reverse on contact with 1-1/2" high (3.
OPERATION IMPORTANT SAFETY INSTRUCTIONS WARNING To reduce the risk of SEVERE INJURY or DEATH: 9. If one control (force or travel limits) is adjusted, the other control may also need adjustment. 10. After ANY adjustments are made, the safety reversal system MUST be tested. 11. Safety reversal system MUST be tested every month. Garage door MUST reverse on contact with 1-1/2" high (3.8 cm) object (or a 2x4 laid flat) on the floor.
Using the Wall-Mounted Door Control To Open the Door Manually Press the push button to open or close the door. Press again to reverse the door during the closing cycle or to stop the door while it's opening. To prevent possible SERIOUS INJURY or DEATH from a falling garage door: • If possible, use emergency release handle to disengage trolley ONLY when garage door is CLOSED. Weak or broken springs or unbalanced door could result in an open door falling rapidly and/or unexpectedly.
THE REMOTE CONTROL BATTERY CARE OF YOUR OPENER LIMIT AND FORCE ADJUSTMENTS: Weather conditions may cause some minor changes in door operation requiring some readjustments, particularly during the first year of operation. Pages 27 and 28 refer to the limit and force adjustments. Only a screwdriver is required. Follow the instructions carefully. Repeat the safety reverse test (Adjustment Step 3, page 29) after any adjustment of limits or force.
HAVING A PROBLEM? 1. My door will not close and the light bulbs blink on my motor unit: The safety reversing sensor must be connected and aligned correctly before the garage door opener will move in the down direction. Bell Wire • Verify the safety sensors are properly installed, aligned and free of any obstructions. Refer to Installation Step 10: Install The Protector System ®. 1 3 2 9 1 7 • Check diagnostic LED for flashes on the motor unit then refer to the Diagnostic Chart on the following page.
Bell Wire Diagnostics Located On Motor Unit 1 2 Installed Safety Reversing Sensor 3 9 1 7 3 9 1 7 3 5 5 KG KG 1 Safety Reversing Sensor Your garage door opener is programmed with self-diagnostic capabilities. The “Learn” button/diagnostic LED will flash a number of times then pause signifying it has found a potential issue. Consult Diagnostic Chart below. “Learn” Button LED or Diagnostic LED Diagnostic Chart 1 FLASH Safety reversing sensors wire open (broken or disconnected).
PROGRAMMING NOTICE: If this Security✚® garage door opener is operated with a non-rolling code transmitter, the technical measure in the receiver of the garage door opener, which provides security against code-theft devices, will be circumvented. The owner of the copyright in the garage door opener does not authorize the purchaser or supplier of the non-rolling code transmitter to circumvent that technical measure.
To Add, Reprogram or Change a Keyless Entry PIN NOTE: Your new Keyless Entry must be programmed to operate your garage door opener. USING THE “LEARN” BUTTON To change an existing, known PIN 1 2 If the existing PIN is known, it may be changed by one person without using a ladder. 3 9 1 7 3 9 1 7 3 5 5 KG KG 1. Press the four buttons for the present PIN, then press and hold the # button. 1 2 The opener light will blink twice. Release the # button. 2.
REPAIR PARTS Rail Assembly Parts 2 1 3 4 5 KEY NO. 6 Installation Parts PART NO. DESCRIPTION 1 4A1008 Master link kit 2 41C5141-1 Complete trolley assembly 3 41A5665-2 Complete rail 4 144C56 Idler pulley 5 41A5807 Chain and cable 6 12D598-1 “U” bracket 183A163 Wear pads NOT SHOWN 4 1 2 3 KEY NO. 6 5 7 10 11 9 8 13 PART NO.
Motor Unit Assembly Parts 1 2 3 19 18 17 15 7 8 9 16 12 14 10 5 4 6 LIMIT SWITCH ASSEMBLY (Down) Contact Brown Wire DN 15 13 UP Drive Gear Center Limit Contact (Up) Contact Grey Wire Yellow Wire 11 PART NO. DESCRIPTION KEY PART NO. NO. DESCRIPTION 1 41A5615 Chain Spreader 11 41R0370-15 Cover 2 41C4220A Gear and sprocket assembly.
ACCESSORIES 953D 3-Button SECURITY✚® Remote Control: 7702CB Required for a garage with NO access door. Includes visor clip. 956D 3-Button Mini-Remote Control with SECURITY✚®: 760CB SECURITY✚® Keyless Entry: 7708CB Enables homeowner to operate garage door opener from outside by entering a password on a specially designed keyboard. Also can add a temporary password for visitors or service persons. This temporary password can be limited to a programmable number of hours or entries.
CHAMBERLAIN SERVICE IS ON CALL HOW TO ORDER REPAIR PARTS OUR LARGE SERVICE ORGANIZATION SPANS AMERICA Selling prices will be furnished on request, or parts will be shipped at prevailing prices and you will be billed accordingly. WHEN ORDERING REPAIR PARTS, ALWAYS GIVE THE FOLLOWING INFORMATION: • PART NUMBER • PART NAME • MODEL NUMBER ADDRESS ORDERS TO: THE CHAMBERLAIN GROUP, INC. Technical Support Group 6050 S.