Chamberlain Power Drive PD428D User manual

The Chamberlain Group, Inc.
845 Larch Avenue
Elmhurst, Illinois 60126-1196
www.chamberlain.com
GARAGE DOOR OPENER
Model PD428D 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
Introduction 2-5
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 .....................................................8-9
Fasten the rail to the motor unit and
install the trolley ........................................................10
Attach the rail brackets..............................................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
Install the Protector System®................................15-17
Position the opener ...................................................18
Hang the opener .......................................................19
Install the door control...............................................20
Install the lights ........................................................21
Attach the emergency release rope and handle .......21
Electrical requirements..............................................22
Complete safety reversing sensor installation ..........22
Fasten the door bracket .......................................23-24
Connect the door arm to the trolley .....................25-26
Adjustment 27-29
Adjust the up and down 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
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
WARNING
CAUTION WARNING
WARNING
WARNING
CAUTION WARNING
WARNING
WARNING
CAUTION
WARNING
WARNING

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 (Optional)
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

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.
Support bracket &
fastening hardware
is required.
See page 19.
— — — — — — — —
Header Wall
Safety Reversing
Sensor
Gap between floor
and bottom of door
must not exceed 1/4" (6 mm).
FINISHED CEILING
Torsion
Spring
Access Door
Motor unit
Wall-
mounted
Door
Control
Rail
Extension
Spring
OR
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 4 – Depending upon garage
construction, extension brackets or wood blocks
may be needed to install sensors.
• Installation Step 4 – Alternate floor mounting of the
safety reversing sensor will require hardware not
provided.
• Installation Step 6 – Do you have a finished ceiling
in your garage? If so, a support bracket and
additional fastening hardware may be required.
Header
Bracket Rail
Bracket
Trolley
Straight
Door
Arm
Emergency
Release
Rope & Handle
Door
Bracket
Garage
Door
Curved
Door
Arm
Garage
Door
Spring
Header
Wall
Rail Assembly
CLOSED POSITION
• 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 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 12).
• 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 (1.2 m) to the left or
right of the door center. See Installation Steps 1
and 12.

5
Access
Door
Safety
Reversing Sensor
Safety
Reversing
Sensor
Header
Bracket
Door
Bracket Straight
Door
Arm
Curved
Door Arm
Trolley
Emergency Release
Rope & Handle
Rail Assembly
Garage
Door
Header
Wall
Rail
Bracket
CLOSED POSITION
Gap between floor
and bottom of door
must not exceed 1/4" (6 mm).
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 12.
• Depending on your door’s construction, you may
need additional mounting hardware for the door
bracket (Step 12).
Safety Reversing Sensor
FINISHED CEILING
Support bracket
& fastening
hardware is required.
See page 19.
Safety Reversing
Sensor
Header Wall
Access
Door
Gap between floor
and bottom of door must not exceed 1/4" (6 mm).
Motor unit
Wall-mounted
Door Control
Rail
ONE-PIECE DOOR WITHOUT TRACK
Header
Bracket Rail
Bracket
Trolley
Straight
Door
Arm
Emergency
Release
Rope & Handle
Door
Bracket
Garage
Door
Curved
Door
Arm
Garage
Door
Spring
Header
Wall
Rail Assembly
CLOSED POSITION
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" (6 mm). 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
Straight Door
Arm Section
Curved Door
Arm Section
Header Bracket
UP
CEILINGMOUNTONLY
Sprocket
Coupling
2-Conductor Bell Wire
White & White/Red
Header/Rail
Brackets
Remote Control
Transmitter Visor Clip
Trolley
Rail Support
Braces (6)
Hanging Brackets
Rail
Assembly
Door Bracket
Multi-Function
Door Control Panel
LOCK
LIGHT
Safety Labels
and
Literature
(2) Safety Reversing Sensors
(1 Sending Eye and 1 Receiving Eye)
with attached 2-Conductor
White & White/Black Bell Wire
Safety Reversing Sensor
Mounting Bracket (2)
Motor Unit with a Light Lens
3-Button Remote Control (2)
Extension Rail
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

7
Lock Nut
1/4"-20x7/16 (16)
Wing Nut
1/4"-20 (2)
Carriage Bolt
1/4"-20x1/2" (2)
Hex Bolt
1/4"-20x5/8" (4) Sprocket Coupling Sleeve
Bolt
1/4-20x1-3/4" (12)
Handle
Nut 5/16"-18 (6)
Ring
Fastener (3)
Clevis Pin
5/16"x2-3/4" (1)
Insulated
Staples (30)
Drywall Anchors (2)
Clevis Pin
5/16"x1" (1)
Rope
Lock Washer 5/16" (6)
Lag Screw
5/16"-9x1-5/8" (2)
Hex Bolt
5/16"-18x7/8" (4)
Clevis Pin
5/16"x1-1/4" (1)
Lag Screw
5/16"-18x1-7/8" (2)
Screw
6ABx1-1/4" (2) Screw 6-32x1" (2)
ASSEMBLY HARDWARE
INSTALLATION HARDWARE
Hardware Inventory
Separate all hardware and group as shown below for the assembly and installation procedures.

8
To prevent INJURY from pinching, keep hands and
fingers away from the joints while assembling the rail.
WARNING
CAUTION
WARNING
WARNING
ASSEMBLY STEP 1
Assemble the Rail
To avoid installation difficulties, do not run the
garage door opener until instructed to do so.
1. Turn the opened rail carton upside down and
empty its contents onto a level work surface.
2. Unfold the rails, taking care to avoid kinking the
screw rod joint.
Center
Rail
Trolley Rack
Extend
End Rails
Outward
Extend
End Rails
Outward
Rail Assembly
Carton
Remove
Cardboard Packing
Remove
Cardboard
Packing
Rail
Support
Braces
Straight
Door Arm
Rail Assembly
Hardware Bag
Chassis Assembly
Hardware Bag
Center Rail
Door End Rail
Rail
Sprocket
Trolley Rack
Sprocket End Rail
Rotate
Extension Rail
NOTE: During assembly, avoid pulling the rail section
housing the trolley rack away from the screw rod.
The rack is factory set about 9" (23 cm) from the end
of the screw rod to the center of the rack.
If the plastic liner slides part way out during
assembly, simply push it back in.
3. Rotate the rail sections so that the flat side is down
and the screw side is up. Keep it clean and free of
debris while you are working.

9
Assemble the Rail (Continued)
4. Beginning with the sprocket end, straighten the
two rail sections so that the screw rod is in a
straight line at the joint. (Avoid handling the joint,
which may have sharp edges.) Connect the
extension rail at the front (header) end of the rail.
5. Carefully slide the pins at the top edge of the rail
into the openings on the adjacent rail. It is
essential that the rail assembly be on a level
surface to achieve proper alignment and to
avoid damage to the pins.
6. Insert two 1/4"-20x1-3/4" bolts through the center
holes of a brace, and place its open length against
the rail at the joint, aligning the holes as shown.
Position another brace on the opposite side of the
rail over the bolts, add 1/4"-20 lock nuts, and hand
tighten. Insert two additional bolts and hand
tighten.
7. Keeping the rail straight and on a level surface,
grasp the screw rods on each side of the
remaining joint and pivot into a straight line.
Repeat steps 5 and 6 for the extension rail
assembly.
8. With a 7/16" wrench, tighten bolts until snug,
beginning with the center holes. Do not
overtighten.
Center Rail
Slide end rail
toward center rail
Rail
Support
Brace
Lock
Nuts
Rail Pin
Alignment
Hole
Rail
Support
Brace
Rail Pin
Alignment
Hole
Bolts
1/4"-20x1-3/4"
Bolts
1/4"-20x1-3/4"
Lock
Nuts
Door End
(Front)
Sprocket End
(Back)
Center
Rail
Rail Pin
Alignment
Hole
End
Rail
Slide end rail
toward center rail
Extension
Rail
Rail
Support
Brace
Lock
Nuts Rail Pin
Alignment
Hole
Bolts
1/4"-20x1-3/4"
Rail Pin
Alignment
Hole
Extension
Rail
End
Rail
Lock Nut
1/4"-20 (12)
Bolt
1/4"-20x1-3/4" (12)
HARDWARE SHOWN ACTUAL SIZE

10
ASSEMBLY STEP 2
Fasten the Rail to the Motor Unit
and Install the Trolley
NOTE: To aid in assembly and installation, replace
the foam packing around the motor unit. Remove it
after Installation Step 4.
• Working on a level surface, align the rail assembly
with the motor unit, as shown.
• Slip the coupling over the rail sprocket.
• Slide the rail through the motor unit bracket until
the coupling fits securely over the motor unit
sprocket.
• Align the two bolt holes in the rail with those in the
motor unit bracket. Insert two 1/4"-20x5/8" hex
bolts and lock nuts. Tighten securely with a 7/16"
socket wrench.
Slide the trolley onto and along the bottom of the
rail until it snaps firmly in place. Be certain to
install it facing correctly: the trolley release
arm must be horizontal (lock position), with its
arrow pointed away from the motor unit.
Rail
Sprocket
Rail
Assembly
Trolley
Coupling
Motor Unit
Bracket
Lock Nuts
1/4"-20
Motor Unit
Sprocket
Foam Packaging
Hex Bolts
1/4"-20x5/8"
Release arm
Arrow must point
toward garage door
Lock Nut
1/4"-20
Hex Bolt
1/4"-20x5/8"
HARDWARE SHOWN ACTUAL SIZE