Chamberlain CG40 Series User manual

The Chamberlain Group, Inc.
845 Larch Avenue
Elmhurst, Illinois 60126-1196
www.chamberlaingroup.com
GARAGE DOOR OPENER
Series CG40
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 end panel of your opener.
®

2
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 T-rail and attach the pulley bracket............8
Install the trolley..........................................................9
Fasten the T-rail to the motor unit...............................9
Install the chain/cable and sprocket cover................10
Tighten the chain and cable ......................................11
Installation 11-27
Installation safety instructions....................................11
Determine the header bracket location................12-13
Install the header bracket..........................................14
Attach the T-rail to the header bracket......................15
Position the opener...................................................16
Hang the opener .......................................................17
Install the door control...............................................18
Install the light and lens ............................................19
Attach the emergency release rope and handle.......19
Electrical requirements..............................................20
Install the Protector System®................................21-23
Fasten the door bracket.......................................24-25
Connect the door arm to the trolley.....................26-27
Adjustment 28-30
Adjust the travel limits...............................................28
Adjust the force.........................................................29
Test the safety reversal system.................................30
Test the Protector System®........................................30
Operation 31-34
Operation safety instructions.....................................31
Using your garage door opener................................31
Using the wall-mounted door control ........................32
To open the door manually........................................32
Care of your garage door opener..............................33
Having a problem?....................................................34
Programming 35-36
To add a hand-held remote control...........................35
To erase all codes.....................................................35
Multi-function remotes...............................................35
To add 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
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.
Mechanical
Electrical
WARNING
CAUTION WARNING
WARNING
WARNING
CAUTION WARNING
WARNING
WARNING
CAUTION
WARNING
WARNING
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.

3
Pliers
Wire Cutters
Claw Hammer
Hack Saw
Screwdriver Adjustable End Wrench
1/2" and 7/16" Sockets
and Wrench
Drill
Tape Measure
2
1
Stepladder
Pencil
3/16", 5/16" and
5/32" Drill Bits
Carpenter's
Level
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.
WARNING
CAUTION WARNING
WARNING
WARNING
CAUTION
WARNING
WARNING
Sectional Door
One-Piece Door

Safety Reversing Sensor
Support bracket &
fastening hardware
is required.
See page 17.
Door
Center
Header Wall
FINISHED CEILING
Torsion
Spring
Extension
Spring
OR
Safety
Reversing
Sensor
Gap between floor
and bottom of door
must not exceed 1/4"
Access
Door
Wall-
mounted
Door
Control
Horizontal and vertical reinforcement
is needed for lightweight garage doors
(fiberglass, steel, aluminum, door with
glass panels, etc.). See page 24 for details.
Motor unit
Slack in chain tension
is normal when
garage door is closed
4
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 Outside Quick
Release is required. See Accessories page.
•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". 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 to the left or right of
the door center. See Installation Steps 1 and 11.
•If your door is more than 7 feet high, see rail
extension kits listed on Accessories page.
Cable Pulley
Bracket
Header
Bracket Trolley
Straight
Door
Arm Emergency
Release
Rope & Handle
Door Bracket
Garage
Door
Curved
Door
Arm
Garage
Door
Spring
Header
Wall
CLOSED POSITION

Access
Door
Gap between floor
and bottom of door
must not exceed 1/4"
Safety
Reversing Sensor
Safety
Reversing
Sensor
CLOSED POSITION
Header
Bracket
Cable
Pulley Bracket
Door
Bracket Straight
Door
Arm
Curved
Door Arm
Trolley
Emergency Release
Rope & Handle
T-rail
Garage
Door
Cable
Header
Wall
Chain
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).
FINISHED CEILING
Support bracket
& fastening
hardware is required.
See page 17.
Slack in chain tension
is normal when
garage door is closed.
Safety Reversing
Sensor
Header
Wall
Safety
Reversing Sensor
Gap between floor
and bottom of door
must not exceed 1/4"
Motor Unit
Access
Door
Wall-
mounted
Door
Control
Cable
Pulley Bracket
Header
Bracket
Trolley
Straight
Door
Arm
Emergency
Release
Rope
& Handle
Door
Bracket
Curved
Door
Arm
Header
Wall
T-rail
Garage
Door
Cable Chain
CLOSED POSITION
ONE-PIECE DOOR WITHOUT TRACK
ONE-PIECE DOOR WITH 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". Otherwise, the safety
reversal system may not work properly.
• The floor or the garage door MUST be repaired to
eliminate the gap.
WARNING
CAUTION WARNING
WARNING

6
Cable Pulley
Bracket
2-Conductor Bell Wire
White & White/Red
Lighted Door Control Button
with (2) screws 6ABx1-1/2"
Trolley
Chain and Cable in
Dispensing Carton
Curved Door
Arm Section
Safety Labels
and
Literature
Sprocket Cover
Rail Brace (3)
T-rail
Center Section
(each) (2)
T-rail
End Section (2)
Straight Door
Arm Section
Hanging Brackets
Header Bracket
UP
CEILINGMOUNTONLY
Door Bracket
SECURITY✚TM
1-button Remote Control
(2) Safety Reversing Sensors
(1 Sending Eye and 1 Receiving Eye)
with 2-Conductor White
& White/Black Bell Wire attached
Safety Sensor
Bracket (2)
Motor Unit with a Light Lens
Your garage door opener is packaged in one carton
which contains the motor unit and the parts illustrated
below. Note that 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

Hardware Inventory
Separate all hardware and group as shown below for the assembly and installation procedures.
7
NOTICE
Lock Washer
5/16" (4)
Nut 5/16" - 18 (4)
Clevis Pin
5/16"x2-3/4" (1)
Handle
Dry Wall Anchors (2)
Clevis Pin
5/16"x1" (1)
Rope
Lock Nut
1/4" - 20 x 7/16" (12)
Nut
5/16" - 18 (5)
Washered Bolt
5/16" - 18 x 1/2" (2)
(mounted in motor unit)
Carriage Bolts
1/4" - 20 x 1/2" (12)
Hex Bolt
5/16" - 18 x 7/8" (3) Master Link (2)
Ring
Fastener (3)
Threaded
Trolley Shaft (1)
Lock Washer 5/16" (4)
Lag Screw
5/16"-18 x 1-7/8" (2)
Wing Nut
1/4x20 (2) Insulated
Staples (30)
Rail Grease
Hex Bolt
5/16"- 18 x 7/8" (4)
Carriage Bolts
1/4"-20x1/2" (2)
Lag Screw
5/16"- 9 x 1-5/8" (2)
Clevis Pin
5/16"x1-1/4" (1)
Self-Threading Screw
1/4"-14x5/8" (2)
ASSEMBLY HARDWARE
INSTALLATION HARDWARE

8
ASSEMBLY STEP 1
Assemble the Rail and
Attach the Cable Pulley Bracket
To avoid installation difficulties, do not run the
garage door opener until instructed to do so.
1.Align the four T-rail sections on a flat surface
exactly as shown. Center sections are
interchangeable. Front and back sections are also
interchangeable for ease of assembly.
2.Insert the carriage bolts so the square
bolt necks seat in the square holes
in the T-rail sections and pass
through the round holes in the rail
braces. Make sure bolt necks are
seated in the square holes and rails
are aligned before you tighten lock
nuts. Improper assembly can cause
jerky trolley operation, noise and/or
nuisance door reversals.
3.Assemble lock nuts, ensure alignment
and tighten.
NOTE: If T-rail is not assembled exactly as shown,
trolley will not travel smoothly along length of rail
or it will hit against nuts.
4.Position the cable pulley bracket on the front end
of the T-rail as shown. Fasten securely with the
hardware shown.
NOTE: When tightening the screws, be sure to
keep bracket parallel to the rail. Otherwise, the rail
may bow when the
opener is operated.
RAIL BACK
(TO MOTOR UNIT)
RAIL FRONT
(TO DOOR)
Cable pulley bracket
attaches to FRONT
END of Rail
Rail
(End Section)
Rail
(Center Section)
Carriage Bolt
1/4"-20x1/2"
Rail
(End Section)
Square Carriage
Bolt Hole
Lock Nut
1/4"
Hex Bolts
5/16"-18x7/8"
Cable Pulley
Bracket
Bracket & Rail Must Be Aligned
Lock Washer
5/16"
Nut
5/16"-18
Lock Nut
1/4"-20
Carriage Bolts
1/4"-20x1/2"
Hex Bolt
5/16"-18x7/8" Nut
5/16"-18 Lock Washer
5/16"
HARDWARE SHOWN ACTUAL SIZE

9
ASSEMBLY STEP 2
Install the Trolley
•Attach the trolley threaded shaft to the trolley with
the lock washer and nuts as shown.
•As a temporary stop, insert a screwdriver into the
hole in the front end of the T-rail.
•Slide the trolley assembly along the rail to the
screwdriver stop.
NOTE: If trolley hits against any nuts on the T-rail,
the bolts and nuts were attached from the wrong
side and must be repositioned. Review Assembly
Step 1.
Temporary Stop
Screwdriver
Trolley
Threaded
Shaft
Inner Nut
5/16"
Lock
Washer
5/16"
Outer Nut
5/16"
Trolley
ASSEMBLY STEP 3
Fasten the T-Rail to the Motor Unit
•Place the opener on packing material to protect
the cover. For convenience, put a support under
the cable pulley bracket.
•Remove the two 5/16"-18x1/2" washered bolts
mounted in the top of the motor unit.
•Align the holes in the back section of the T-rail with
the holes in the motor unit.
•Fasten the rail with the two washered screws
previously removed. Tighten securely. Remember
to use only these screws! Any other screws
will cause serious damage to the opener.
•Insert a 5/16"-18x7/8" hex bolt into the cover
protection bolt hole in the T-rail as shown. Tighten
securely with a 5/16" lock washer and nut.
NOTE: This screw prevents trolley over-travel. Keep
a 2" minimum between the trolley and this screw
when adjusting travel limits (see page 28).
Washered Bolt
5/16"-18x1/2" USE ONLY THIS
TYPE AND SIZE
SCREW
T-Rail
(Back Section)
Cover
Protection
Bolt Hole
Nut
5/16"-18
Hex Bolt
5/16"-18x7/8"
Lock Washer
5/16"
Nut
5/16"-18 Lock Washer
5/16"
Hex Bolt
5/16"-18x7/8"
HARDWARE SHOWN ACTUAL SIZE
To avoid serious damage to opener, ONLY use
bolts/fasteners mounted in top of motor unit.
WARNING
CAUTION
WARNING
WARNING
Lock Washer
5/16" Nut
5/16" -18
HARDWARE SHOWN ACTUAL SIZE

10
ASSEMBLY STEP 4
Install the Chain/Cable
and Attach the Sprocket Cover
INSTALLING THE CHAIN/CABLE
1.Pull the cable loop from
the carton and fasten it
to the trolley with a
master link from the
hardware bag (see
Figure 1).
• Push pins of master
link bar through cable
loop and hole in front end of trolley.
• 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.
2.With the trolley against the screwdriver,
dispense the cable around the pulley.
3.Continue along the rail and around the motor
unit sprocket (Figure 2). The sprocket teeth
must engage the chain. Continue forward to
the trolley threaded shaft.
4.Use the second master link to connect the
chain to the flat end of the shaft (Figure 1).
Check to make sure the chain is not
twisted.
5.Remove the screwdriver.
ATTACHING THE SPROCKET COVER
Insert the back tab in the slot on the back of the
mounting plate. Squeeze the cover slightly and insert
the front tab. (Figure 3).
To avoid possible SERIOUS INJURY to fingers from
moving garage door opener:
• ALWAYS keep hand clear of sprocket while operating
opener.
• Securely attach sprocket cover BEFORE operating.
WARNING
CAUTION WARNING
WARNING
Motor unit
Sprocket
Figure 2
Sprocket
Cover
Mounting
Plate
Front Tab Slot
Back Tab Slot
Figure 3
Cable
Pulley
Cable
Loop
Master
Link Bar
Master Link
Clip-On Spring
Trolley
Rail
Pin
Pin Notch
Chain
Flat end
of Trolley
Threaded Shaft
Master
Link Cap
Master
Link Cap
Master Link
Clip-On Spring
INSTALL CHAIN & CABLE
IN THIS DIRECTION
Figure 1
Leave Chain &
Cable Inside
Dispensing
Carton to
Prevent Kinking
Keep Chain and Cable
Taut When Dispensing